BUILD MANUAL EV97 team EuroStar

EV97 team EuroStar
BUILD MANUAL
ISSUE 2 2011
1
Aerotechnik EV-97 team Eurostar (Issue2 January 2011)
Introduction,
These instructions follow the exact sequence used by Light Sport Aviation
when building type approved aircraft and have proven to be a logical and
efficient sequence with the facilities we have, individual kit builders may wish
to adjust the sequence to suit their personal requirements/facilities.
We have tried to be specific with these instructions and have included many
drawings/photos, but if something does not make sense please phone us and
ask (input about these instructions will be gratefully received).
Before starting the assembly of your Eurostar please contact the LAA (Light
Aircraft Association) and register your build. An inspection of the kit and your
workshop is required by a LAA inspector before work commences.
General notes
Aerotechnik use bolts to an East European aircraft standard which have
several features that the builder should be aware of.
The bolt shanks are ground to close tolerances and have no corrosion
protection; consequently all such bolts should be assembled with Castrol LM
grease or similar, whatever the application.
There is a sharp undercut at the shank where it joins the thread, this means
that full bearing area can be obtained even in thin sheet components,
provided attention is paid to bolt length, washer thickness and position.
It is possible when assembling, for a washer to get trapped in the undercut
between the nut and the sharp end of the shank if the shank protrudes
beyond the surface of the component being bolted. Care must be taken to
avoid this situation as it can lead to loss of clamping force. These instructions
detail the part number and position of washers which will give the correct fit to
the bolt /assembly. Washers of different thickness are used at specific
locations to give the correct fitting of the bolts and ensure the shank bears
correctly.
Rivnuts are used in a number of locations on the aircraft. A tool for installing
these can be either purchased from an aircraft tool supplier or Light Sport
have one that can be lent to you. If you do purchase or borrow one make sure
it is the metric version.
Emfimastic is widely used on theEurostar, this is a multi purpose non-rigid
compound which is used as a sealant, an adhesive and a jointing compound
or gap filler. Use Emfimastic sparingly so as not to add unnecessary weight.
Emfimastic can be smoothed with a finger wetted in washing up liquid. To
remove Emfimastic when it is still wet we have found methylated spirit to be
the safest, once dry acetone can be used to remove it but do not use acetone
on any of the canopy transparencies or on any painted surfaces. It can be
made easier to remove using a bit of heat from a hot air gun (caution as
getting the aluminium too hot will crack the anodising).If Cleco’s are used
when assembling a joint using Emfimastic, clean the Cleco’s immediately after
use before the Emfimastic dries.
2
The control rod end bearings and the bearings used on the rudder hinge may
be of the type where the spherical bearing is inserted through a loading slot
into the housing. In such rod ends the bearing is not positively retained until
assembly and can fall out. It is good practice to put a piece of locking wire
through the rod end eye if there is a chance of the bearing coming out, if, for
instance the wings and / or tailplane are removed for transport.
There are many lock nuts on the aircraft, for instance on control rod end
fittings and control stops. These should be painted with a red line (either a
commercially available “anti tamper” paint or red nail varnish) across a fixed
point to make later inspection for loose nuts easier. We tend to mark all
nuts/bolts with a red line as a final check mark out of habit.
The aircraft is mainly constructed using “pop” rivets and to prevent water
getting onto the steel pin inside the rivet, each rivet requires filling with
Emfimastic. We fill every rivet we can get to, some require filling before being
made inaccessible by the fitting of other components, for example the fin spar
rivets require filling before fitting the rudder.
We use a syringe to fill the rivet head and then wipe off any excess with a
cloth (see pictures below)
FILL RIVETS USING
EMFIMASTIC IN A SYRINGE
WIPE OFF EXCESS
WITH RAG
The aircraft we built and photographed for these instructions had all of the
composite components painted silver, we painted the interior, floor and
instrument coaming matt black before assembly began. You may wish to do
this if like us you intend to leave the aluminium un-painted. If you are
intending to paint the whole aircraft carefully consider the build sequence so
as to fit the painting in at the correct point.
3
Modifications.
The LAA have required five modifications to be installed at the factory to
comply with UK requirements. These are:LAA 315-001. An additional support for the long aileron push rod at rib 5.
LAA 315-002. An additional bracket similar to the one supporting the flap torque
tube centre bearing to give better support to the elevator reverse
lever mounting.
LAA 315-003. Two additional stiffeners on the fin leading edge skin.
LAA 315-004. Improved outer lap strap attachment with spacer tube and large
washer.
E4 01-2201. Shortened control sticks.
Your inspector should check that Aerotechnik has incorporated the first three,
and that the parts have been supplied correctly for the builder to comply with
the last two.
Light Sport Aviation issue service bulletins from time to time and a copy of all
existing bulletins and any necessary components are included with the kit.
At January 2011 the following have been issued.
SB EV97-UK-01 Loctite on flap lever nut (applicable only to existing aircraft without
two tab washers).
SB EV97-UK-02 Loctite on throttle control screw (applicable to all aircraft during build
and retrospective).
SB EV97-UK-03 Vent hole in fuel filler cap (Existing aircraft without separate drain
and vent).
SB EV97-UK-04 longer rivets in bearing brackets (applicable to all aircraft during
build and retrospective).
SB EV97-UK-05 Loctite on fuel taps (applicable to all aircraft during build and
retrospective).
SB EV97-UK-06 Insulation of exposed terminals (applicable to all aircraft during build
and retrospective).
SB EV97-UK-07 Coolant overflow bottle (applicable to all aircraft during build and
retrospective).
SB EV97-UK-08 Trim cable clevis pin retainer (applicable to all aircraft during build
and retrospective).
SB EV97-UK-09 Possible corrosion of pitch trim cables (applicable to all aircraft)
SB EV97-UK-10 Inspection of top rudder bearing (applicable to all aircraft)
SB EV97-UK-11 (MPD 2010-003)
Checking the strength of the lower wing spar caps. (applicable to all aircraft)
This will have been carried out before you received your kit and a declaration
of conformity supplied
Rotax mods and bulletins are promulgated via a variety of instructions. All
new engines are delivered to the latest standard and all known owners are
sent mandatory bulletins via Email when Rotax issues them. All bulletins can
be accessed from the Rotax website, www.rotax-aircraft-engines.com. There
are two instructions/bulletins that apply to all engines when new and
throughout their life.
SI-912-018 Purging of lubrication system.
SI-912-016 R2 Selection of suitable operating fluids.
Copies of these or later revisions are included with the engine paperwork, or
can be found in the engine installation instructions (on the CD supplied with
the engine).
4
Inventory check
The inventory check is an important early task because any kit shortages
should be notified to Light Sport within six weeks of kit receipt .It is also useful
in getting the builder familiar with the bag and part numbering system and the
parts themselves.
DO NOT EMPTY ALL THE PARTS FROM THE NUMBERED BAGS!
Always during the build remove the required parts from the numbered bags,
replace any parts not required back into the bag and re-seal it, or alternately
use numbered boxes
Build sequence
As stated earlier the following is the build sequence we use at Light Sport
when assembling the type approved aircraft and using pre-painted
composites and cockpit interior. This sequence may need to be altered to suit
individual builders preferences and/or if the builder intends to paint the whole
aircraft. A set of engineering drawings is included in every kit and can be
referred to if necessary.
Before starting work remove from the fuselage, the scuttle panel, canopy, rear
luggage bay floor, seat pans (all of these have been temporarily fitted for
transport).
We think it easier to work on the fuselage with it just off of the ground; the
polystyrene blocks used in the wing box as packaging are ideal to place under
the main spar carry through and under the tail, however, if you prefer to work
with the fuselage at a higher level lifting it onto suitable trestles and fitting the
undercarriage first may suit.
Inspections
Three stage inspections are identified i.e. points where a visit by your LAA
inspector is essential. This is a a minimum and individual inspectors may wish
to visit more often, discuss this with your inspector before you commence the
build.
1st inspection. Inspection of kit as supplied, inclusion of LAA mods and
inspection of workshop facilities.
2nd inspection. Inspection of all systems etc before closing in with rear side
panels and seat pans etc.
3rd inspection. Final inspection before application to the LAA for flight test
authorisation. The aircraft should be fully assembled and ready for flight but
with all inspection covers removed. The aircraft will be weighed and a weight
and CG report completed. The engine should be run, carburettors balanced
and idle speed set, fuel flow checks will be carried out. In addition to the LAA
paperwork the Skydrive checklist should be completed.
5
First job is to trim the excess from the top of the fin skin, mask off and trim as
shown in the picture below.
Use a Dremel or similar tool fitted with a cutting disc to cut the excess
from the top of the fin front skin fin.
6
Mark out and drill 3.2mm the holes for riveting the fin top fairing on. Holes
should follow the line of the existing rivets and be 10 mm from the edge.
10
45
45
43
40
10
Remove the masking tape and de-burr the holes.
7
Set the position of the top rudder hinge as diagram and photos below, apply
loctite 648 on the threads before doing up the plain nut and then bend lock tab
to secure as in the drawing below. NOTE a recent change of the position of
the locktab to between the plain nut and the fin spar with the long tab bent
forward into recess in spar and onto the stiffnut and the two triangular pieces
bent up to secure the plain nut.
Plain nut (apply loctite 648 to thread before
tightening)
Lock tab
Stiff nut
Fin spar
Set this distance to 31 mm
8
Fit the rudder onto its two hinges; make sure it is fully seated into the lower
hinge. The fin top fairing 8515 (bag No2) can now be positioned (it fits inside
the fin skin) once you are happy with the alignment drill and cleco into place.
Remove the rudder (this may require removal of the clecoed on fairing). The
rear edge of the fairing will need trimming to match the edge of the fin spar
and to allow the rudder to be removed and re-fitted and requires three more
holes 3.2 mm, 10 mm in from the edge, drilled each side to rivet the fairing to
the fin spar.
Remove the fin top fairing and de-burr the holes. Apply emfimastic to the
contact surfaces and rivet the fairing in place using 3.2 X 7.9 rivet 6472 (bag
No 2), clean off any excess emfimastic.
Now is a good time to fill all the rivet heads in the fin spar, the fin and the
rudder.
Trim rear edge level
with spar and make
sure rudder can be
removed and refitted, if not trim a
little from the top
rear edge to clear
50
50
10
10
9
Tailplane Rivnuts. (Bag 24)
Remove orange transport bracket from rear fuselage, temporarily fit tailplane
using the two plain nuts from the transport bracket.
Mark positions of holes as illustrated below, drill 3.2 mm and cleco fairing to
tailplane, push and hold the fairing inwards towards fin/fuselage to get a nice
fit before drilling.
Temporarily secure tailplane using
plain nuts from transport bracket
Top of tailplane fairing
10
90
90
70
70
40
10
Underside of tailplane fairing
100
110
40
110
Remove tailplane (discard plain nuts as these are no longer required), open
the holes in the tailplane skin to 6mm diameter and de-burr. Using the correct
tool fit rivnuts 6980 (bag No24) into the tailplane skin, apply a little loctite 648
to the outside of the rivnut before fitting. Open the holes in the tailplane fairing
to 4mm diameter.Now is a good time to fill all the tailplane rivets with
Emfimastic.
11
Upper and lower trim cable guide tubes. (Bag 37)
Drill through the hole in the lower rudder pivot-bearing bracket and through
the rear spar in between the two rivets 6mm diameter, open this up to 8mm
diameter and de-burr the holes. Cut a piece of tube 8483 (bag no 37) 50mm
long and push it into the holes so it protrudes a couple of mm beyond the
rudder bearing bracket, secure in place with a bead of Emfimastic.
It is useful at this point to glue the remaining piece of tube 8483 to the rear of
one of the long elevator pushrods (rod 8687) with Emfimastic; it should be
positioned on the side of the pushrod. Hold in place with a couple of cable
ties.
Drilling for upper trim cable guide tube
Upper guide tube fitted and secured with Emfimastic
Lower guide tube glued to pushrod 8687
12
Final installation of rudder. (Bag 24)
Grease both upper and lower rudder pivots and install rudder, secure with
washer M5 (21933), nut M5 (3082) and split pin (3183) all from bag No 24.
FROM BAG 24
WASHER M5
21933
NUT M5
3082
SPLIT PIN
3183
Rudder cables and guides. (BAG 36)
Assemble rudder cable ends as shown below, screw the cable termination
(9576) fully onto the cable (8841) and then back it off a couple of turns before
locking with nut (52041). Apply a red paint line across the nut and cable
termination.
CABLE 8841
NUT 52041
CABLE TERMINATION 9576
13
Feed the assembled cables through the holes in the fin rear spar and through
the two guide tubes in the fin front spar. Be careful not to cross the cables and
make sure they route on top of the fin lower rib.
Connect the cables to the rudder as per pictures below; note the position of
the two 6mm washers (6813) on top of the cable termination, these are to
prevent the cable termination rubbing on the fin.
LOCK TAB 6.2 (8528)
CABLE TERMINATION
WASHER 6.4 (6813)
SCREW 6 X 23
(62369)
14
2 X WASHER 6.4 (6813)
Make up the two rudder cable guides and slide onto the cables, these will be
positioned and fixed later.
NUT M4 (3088) X4
WASHER 4.3
(6812) X4
BOLT M4 X 10 (50482)
TUBE (8483) 50 MM LONG
LOOP 1 X8 (55735)
The remaining two bolts,
washers and nuts will be
used to secure the guides to
the airframe at a later time
15
FRONT
Slide guide tube (8483) through the fuselage side stiffeners and the rear
bulkhead by approximately 25 mm, cut off 6mm forward of front stiffener. The
small cut outs on the stiffener directly in front of the seat back may need a
little filing to allow a straight run.
GUIDE TUBE 8483, FEED THROUGH
APPROXIMATELY 25MM
GUIDE TUBE (8483) THROUGH
STIFFENER BETWEEN REAR
BULKHEAD AND SEAT BACK
16
CUT OFF GUIDE TUBE
APPROXIMATELY 6 MM
INFRONT OF STIFFENER
FILE CUT OUT IN STIFFENER
IF REQUIRED
Feed the rudder cables through the guide tubes, have either an assistant or
use bungee cord to pull both cables taught. With the cables taught the rear
guides can be located and holes drilled to secure them with M4 bolts and
nuts.The brackets may need bending a little to get a good fit.
WITH CABLES PULLED TAUGHT, ALIGN BRACKETS AND DRILL
M4
BOLT 4 X 10 (50482)
WASHER 4.3 (6812)
NUT M4 (3088)
FRONT
17
This next item may have already been carried out by the factory.If not follow
instructions below
Using the stop plates (shim 8414) mark the positions of the slots for the
rudder cables to pass through the two vertical stiffeners above the main spar.
Note the plates have offset slots in them and the slots in the rear stiffeners
has to be higher than the front ones, this is because the rudder cables run
downwards through the nylon blocks (8471 & 8470) towards the rudder
pedals. Drill the marked slots and using a needle file open to the required
size.
Fit stop plates (8414), nylon stop blocks (8471 & 8470) using bolts 6 X 35
(47334) and nuts (3089), the bolts should be fitted with the heads forward.
(8470)
STOP PLATE (8414)
NUT M6
(3089)
(8471)
BOLT 6 X 35
(47334)
MARKING FRONT (LOWER) SLOT. FOR REAR SLOT TURN PLATE
OVER SO SLOT IS UPPERMOST.
18
NUT M6
(3089)
BOLT 6 X 35
(47334)
STOP PLATE (8414)
STOP BLOCK (4871 / 4870)
STOP BLOCK AND PLATES
FITTED
Assemble the adjustable stops, and slide the rear one onto the rudder cable
complete with nocopress sleeve and heat shrink tube, feed the cable through
the stop blocks and slide on the front stop (note the order and orientation of
components). Cut two pieces of tube (8483) 410 mm long and slide this onto
the cable, fit a piece of heatshrink tube 50 mm long onto the cable followed by
a nicopress sleeve, loop the cable through the sleve. The rudder cables will
be completed after the nose wheel and rudder pedals are fitted.
NUT M6
(52041)
ADJUSTER (43110)
NUT M6
(52041)
ADJUSTER
BOLT (43111)
ADJUSTER
BOLT (43111)
NICOPRESS
SLEEVE (8256)
HEATSHRINK TUBE
(53852) 40 MM LONG
19
NICOPRESS
SLEEVE (8256)
TUBE (8483)
410 MM LONG
HEATSHRINK TUBE
(53852) 50 MM LONG
Drill holes as shown in the pictures below, most of these will be used at a later
stage but it is easier to mark and drill these before other components are
fitted.
DRILL 8MM DIAMETER AND FIT GROMMETS 3783 (BAG No 37) FOR TRIM
CONTROL CABLES TO PASS THROUGH REAR BULKHEAD
20
60
30
10
20
DRILL BOTH FUEL TANK SUPPORTS 4 MM
DIAMETER (THESE ARE FOR ATTACHING
FUEL TANK BONDING STRAPS AT A
LATER STAGE.
20
Fit the cable end fittings 3554 (bag No 37) into their pre-drilled holes adjacent
to the flap lever mounting brackets.
END FITTING 3554
(BAG 37)
DRILL HOLE 2.5 MM IN LEFT HAND FUEL TANK / ELEVATOR REVERSE LEVER
SUPPORT MEMBER (THIS IS TO SECURE TRIM CABLES AT A LATER STAGE)
60 (APPROX)
DRILL HOLE 2.5 MM DIAMETER IN THE LEFT HAND SIDE OF THE REAR
SPAR CARRY THROUGH JUST ABOVE THE LIGHTENING HOLE (THIS AGAIN
IS FOR SECURING THE TRIM CONTROL CABLES AT A LATER STAGE
15
21
Fuel filler neck (Bag 46) Align the cast aluminium filler neck housing
(30625) from inside the fuselage, this needs to be as high and as far back as
it can go (touching both the top longeron and the side stiffener). From the
inside drill 3.2mm through the pre drilled holes in the casting and through the
fuselage side skin, use clecos to hold in place (a hole dinder can be used if
your drill is too big to drill all the holes).
ADDITIONAL FLAT CUT OFF OF
HOUSING IS NOT NECESSARY
With the housing removed make a template using masking tape for cutting the
hole in the fuselage side skin to suit the housing. We use a dremel and a
cutting disk, finishing with a flap wheel and fine emery paper. De-burr all
holes, apply emfimastic and rivet housing in place using 3.2 X 7.9 rivets
(6472)
22
Fuel taps (BAG 46)
Fuel feed tap
Assemble fuel feed tap as shown below (bag No 46), use loctite 648 on the
threads (SB EV97-UK-05),remove the operating lever, rotate it 180 degrees
and re-fit it. This tap is then fitted to the left hand fuselage side stiffener just
below the instrument panel.
FUEL TAP (7243)
FITTING (7921)
APPLY LOCTITE 648
TO THREADS
NUT (41821)
WASHER (3118)
FITTING (18971)
REMOVE
OPERATING
LEVER AND
ROTATE 180
DEGREES AND
RE-FIT
FUEL FEED TAP ASSEMBLY
NUT (41821)
WASHER (3118)
FUEL FEED TAP FITTED
23
Fuel drain tap
Assemble fuel drain tap as shown below (bag No 46), use loctite 648 on the
threads (SB EV97-UK-05),remove the operating lever, discard the original
screw
WASHER (3118)
NUT (41821)
FUEL TAP (7243)
FITTING (7921)
EXTENSION TUBE (7397)
FITTING (18971)
APPLY LOCTITE 648
TO THREADS
DISCARD ORIGINAL SCREW
HOLDING OPERATING LEVER
SCREW M3 X 25
(54353)
FUEL DRAIN TAP
Loosely fit the drain tap assembly into its bracket on the right of the fuel tank
bay (without the extension tube or lever attached) and mark the centre for the
hole in the fuselage side. Drill this hole just large enough to fit the extension
tube through
WASHER (3118)
NUT (41821)
DRILL FUSELAGE SIDE TO
CLEAR EXTENSION TUBE
DRAIN TAP LEVER FITTED
24
Drill two holes 10 mm diameter as shown in the picture below, fit grommets
3785 (bag No 46), cut a piece of 7254 (bag No 46) clear tubing 160 mm long,
fit to fuel drain tap using cobra clamp 3739 (bag No 46) and push the other
end through the rearmost grommet.
DRILL 10 MM
DIAMETER
PIPE (7254) 160 MM LONG
.
15
15
80
COBRA CLAMP 10/7 (3739)
Flap torque tube and operating lever. (BAG 36)
Slide flap torque tube (E4 01-07 01) through hole in right hand fuselage side,
note the flat side of the welded on stop ring goes inwards .Fit centre bearing
(6876) over the torque tube before the tube passes through the two centre
webs. Use packing pieces to align the torque tube parallel to the rear spar and
centred in the two outer holes (some of the holes in the webs may need filing
a little to give clearance. Drill through the centre-bearing block fixing holes
(4MM diameter) into the right hand centre web; secure block to web with M4
screw (47214), washer (6812) and nut (3088).
E4 01-07 01
FLAT SIDE OF STOP RING INWARDS
25
Bearing block
(6876)
Screw M4 X 20
(47214)
Nut M4 (3088)
Washer 4.3 (6812)
Fit the left hand outer bearing block.
Bearing block
(9946)
Screw M4 X 20
(47214)
Nut M4 (3088)
Washer 4.3 (6812)
26
The right hand bearing block can now be offered up and the holes for the
fixing bolts drilled ready for fitting at a later stage.
Slide the torque tube out enough to be able to fit the lever (8451), with its pre
drilled hole upwards and the lever pointing forwards, in between the two
centre webs.Slide the torque tube back into position so its stop ring is up
against the centre bearing, slide lever (8451) up against the inner face of the
right hand inner web (the one with the bearing block on the other side). The
lateral position of this lever is what sets the end float of the flap torque tube,
ideal is 1 mm. Whilst holding everything in position drill through the pre drilled
hole in the lever into the torque tube but not all the way through (a long series
4mm drill is ideal for this). Put a couple of marks to show the orientation of
lever to torque tube and then remove them from the aircraft.Re-assemble the
lever onto the torque tube and using a pillar drill and suitable blocks drill
through 4mm and then open up to 5.8mm and ream to 6mm.
DRILLING PILOT HOLE FOR POSITIONING FLAP
TORQUE TUBE LEVER
PUT A MARK
ACROSS HERE TO
SHOW ALIGHNMENT
OF PARTS
USING A PILLAR DRILL AND
SUITABLE BLOCKS, ALIGHN
HOLE ALREADY MADE AND
DRILL THROUGH 4 MM
DIAMETER, OPEN THIS TO A
FINISHED SIZE 6MM
27
Adjust pushrod (E4 01-17 01) to 465 mm from centre to centre of the rose
joints, tighten lock nuts making sure both joints are in line with each other and
bend lock tabs to secure. Assemble to flap lever (8456) using pin (6880),2 X
lock tabs (8528) and nut (3062). Light Sport SB EV97-UK-01 is applicable to
this area but only to aircraft built with a lock tab only on one side. For extra
safety it is worth putting a little loctite 221 on the bolt. Once secure the lock
tabs can be bent over (cut the long tang of the lock tabs to prevent them
fouling on the ball joint). Using bolt 6 X 23 (62369) attach the flap torque tube
lever (8451) to the other end of the push rod.make sure the lever (8451) is the
correct way around and note the orientation of the bolt. Secure bolt with
washer (6813), nut (3062) and split pin (8530).
465 MM
PUSH ROD E4 01-17 01
NUT 3062
PIN 6880
LOCK TAB
8528
SPLIT PIN
(8530)
BOLT M6 X 23
(62369)
NUT
(3062)
WASHER
(6813)
28
Grease spacer (6777) and slide it into the hole in the base of the flap control
lever (8456). Position lever / pushrod assembly into fuselage, passing
pushrod and one-armed lever through hole in centre fuselage brace.
SPACER (6777)
SLIDE ASSEMBLED FLAP LEVER,
PUSHROD AND ONE ARMED
LEVER INTO POSITION
Once the flap lever, pushrod and one armed lever are in position slide the flap
torque tube into position, pasing it through the one armed lever. Fit the right
hand flap torque tube bearing.
Right hand flap torque tube bearing block
Bearing block
(9946)
Screw M4 X 20
(47214)
Nut M4 (3088)
Washer 4.3 (6812)
29
Line up the holes in the flap torque tube and the one armed lever and fit bolt 6
X 33 (2839) from the front (this bolt has to be fitted this way, with the nut
uppermost as there is insufficient clearance to have the nut at the bottom). Fit
washer (6813), which may need flats filing on it to fit between the two webs of
the lever.Fit and tighten nut (3089).
NUT M6 (3089)
WASHER 6.4
(6813)
BOLT 6 X 33 (2839)
Using a 90° countersinking bit countersink the flap lever gates (8378) at the
upper rear fixing points to accept screw M6 X 12 (21916). Make sure to
countersink from the correct sides of the gates so as to make left and righthanded flap lever gates.
90°
LEFT HAND FLAP LEVER GATE
SHOWN, RIGHT HAND ONE SHOULD
BE MIRROR IMAGE
Fit bolt 6 x 29 (62370) from bag No 37 (trim control) into left hand flap gate,
this is the pivot for the trim control lever and cannot be fitted once the gate is
fitted. Apply a spot of loctite 648 to secure and position so the split pin hole
will be vertical once the gate is fitted.
30
Assemble flap gates to airframe; the locking pin in the flap control lever will
need removing (held by split pin) and then re-fitting after the two gates are
fitted. Note orientation of bolts .Cut down a 4MM Allen key to enable
tightening of the countersunk screws.
A
C
B
SCREW 6 X 12
(21916)
WASHER 6.4
(6813)
A
WASHER 6.4
(6813)
B
NUT M6
(3089)
SCREW 6 X 29
(62370) FROM BAG 37
WASHER 6.4
(6813)
BOLT 6 X 43
(2892)
NUT M6
(3089)
C
SPACER TUBE
(6776)
NUT M6
(3089)
WASHER 6.4
(6813)
SPACER TUBE
(6777)
BOLT 6 X 41
(8491)
31
Hand control system
Pushrods and levers. (Bag No 35 and loose parts)
Short pushrod (8686) needs to be set to 723 mm to rose joint centres and the
locknuts tightened, apply red paint across the lock nuts to make future
inspection easier. Fit bearings (9052) into the elevator two armed lever pivot
brackets (these fit from the inside and should have loctite 648 applied to
them). Assemble pushrod (8686) to the bottom of two armed lever (note
orientation of bolt), insert rod / lever assembly in through holes in main spar
and undercarriage cross member. Fit lever onto bearings as pictured below.
Note bolt (2847), whish is fitted from right to left, cannot be fully tightened or it
will prevent free movement of the arm. Grease all moving parts on assembly.
BEARING
(9052)
Apply loctite
648 to
secure
B
SCREW (2847)
BEARING (9052)
WASHER
(6813)
A
NUT (3062)
SCREW 6 X 23
(62369)
WASHER
(66302)
NUT (3062)
SPLIT PIN
(8530)
WASHER 6.4
(66302)
B
SPLIT PIN
(8530)
A
NOTE BOLT GOES LEFT TO RIGHT
32
Fit elevator single arm lever (E4 01-19 01) at position midway along rear
fuselage, again this should only be tightened enough to remove any play but
still allow free movement of the arm. Adjust pushrod (8687), the one without
the guide tube glued to it, to 1486 mm and tighten the lock nut, fit this as
shown below (the adjustable end goes forward onto the two-armed lever).We
grind 1mm off of the end of screw 6 X 21 (2833) to give better clearance
between it and the upright. Now fit the second long pushrod (the one with the
guide tube glued to it) fit it with the guide tube on the left. The length of this
will be set when the control deflections are set so the lock nut can be left
loose.
C
SCREW 6 X 23
(62369)
NUT (3062)
C
PUSHROD (8687)
ADJUSTABLE
END TO TWOARMED LEVER,
FIXED END TO
SINGLE-ARMED
LEVER
WASHER 6.4
(6813)
SPLIT PIN
(8530)
WASHER 6.4
(66302)
D
D
FRONT
SPLIT PIN
(8530)
SCREW
6 X 49
(9056)
NUT (3062)
WASHER 6.4
(66302)
SINGLE-ARMED LEVER
(E4 01-19 01)
NUT (3062)
E
SPLIT PIN
(8530)
SCREW
6 X 21
(2833)
WASHER 6.4
(66302)
E
33
PUSHROD EXIT AT TAIL, NOTE TRIM CABLE GUIDE TUBE ON
LEFT SIDE.
ELEVATOR PUSHROD CONNECTION TO TOP OF TWO-ARMED LEVER.
Control stick and cross tube. (Bag No 35 and loose parts)
Set control rod (8734) the same length as the distance between the control
stick pivots in the control lever body/ cross tube (8685). The easiest way to do
this is to use two bolts through the pushrod ends and adjust the rod until it fits
exactly to the control body.
SET LENGTH OF PUSHROD (8734) TO MATCH DISTANCE BETWEEN
STICK PIVOT HOLES
34
Assemble one control stick to pushrods and then insert it into the control stick
housing passing it in far enough to be able to assemble the opposite side. The
short pushrod (8688) should have the inner (8mm threaded) rose joint wound
all the way in and then undone ½ a turn and locked with nut. Leave the outer
rose joints loose at this time. Note the sticks are assembled so they angle
towards the pilot and are assembled into the control lever body with the
connection on the body for the elevator pushrod to the left (as viewed from the
rear) see drawing below.
HAND CONTROL ASSEMBLY
VIEWED FROM REAR
SPACER (12096)
CONTROL LEVER
BODY (8685)
CONTROL STICK (14290)
ROD (8688)
A
35
A
ROD (8688)
BOLT 6 X 25 (62368)
PAD (8195)
CONTROL STICK (14290)
WASHER (15003)
NUT (3070)
SPLIT PIN (8530)
ROD (8734)
ASSEMBLE SECOND STICK TO PUSHROD AFTER INSERTING
INTO CONTROL LEVER BODY
Assemble both
sticks to control
lever body as
shown, Note the bolt
goes in from the rear
as this is used as
the elevator back
stop.
SPLIT PIN
(8530)
SCREW
6 X 49
(9056)
NUT (3062)
WASHER 6.4
(66302)
36
Check the fit of bearing blocks (9696) on the control lever body, they may
need a little re-working to achieve a free rotating fit. When a good fit has been
achieved the hand control assembly can be fitted into the fuselage using the
bearing blocks and bolts as below. Once the bearing blocks are tightened up
re-check for free movement (sometimes a tap with a hammer helps to “settle”
things in. Connect the elevator pushrod to the lever under the control body.
SCREW M5 x 70
(9652)
LOCK TAB 5.3
(3141)
BEARING BLOCK
(9696)
NUT (3062)
SCREW 6 X 23
(62369)
BEARING BLOCK
(9696)
LOCK TAB 5.3 (3141)
BEND TO SECURE
AFTER TIGHTENING
SCREWS
SPLIT PIN
(8530)
WASHER 6.4
(66302)
SCREW M5 X 70 (9652)
37
Trim control system (bag No 37)
Feed the outer cable (3558) in from the rear of the fuselage, one end in
through the guide tube in the fin spar, through a cable tie around the front left
hand tail plane support bracket then down and along the lower fuselage
stiffener, passing through the holes in the cross members, through one of the
grommets in the cockpit rear bulkhead, over the top of the flap torque tube,
through the rear spar cross member and onto the top end fitting fitted earlier.
The other end of the outer cable should be fed through the guide tube on the
elevator push rod, along the pushrod (loosely secure with a couple of cable
ties) and then, aft of the elevator single armed lever, it drops down and follows
the other cable forward and on to the lower end fitting. With both cables
seated in the front end fittings work backwards securing the outer cables with
cable tie (13392).
General layout of trim cables
5
4
1
2
3
1
2
CABLE TIE (13392)
CABLE TIE (13392)
3
DRILL HOLES 2.5 MM IN STIFFENER
FLANGE AND SECURE CABLES WITH
CABLE TIE (13392)
4
ROUTE LOWER CABLE ONTO PUSHROD
LEAVING A “LOOP” TO ALLOW
MOVEMENT OF THE ELEVATOR PUSHROD,
SECURE WITH CABLE TIES
38
SECURE UPPER CABLE TO
TAILPLANE FRONT MOUNTING
BRACKET WITH CABLE TIE
5
Cut the cable in two at the rear and fit the tailplane (only temporarily if the
aircraft is going to be painted or the tailplane removed for transport). Grease
the front fitting pins before fitting the tailplane. (BAG 24)
CUT THE OUTER CABLE IN TWO AT
THE TAIL
WASHER
(7738)
NUT (3071)
SPLIT PIN (37002)
TAILPLANE SECURING
Cut both outer trim control cables to length; make sure there is sufficient
length to allow full movement of the elevator without stretching the cable. Fit
end cap (3551) to all four ends; also slide a piece of heat shrink tubing over
each end (53852) left over from the rudder cables.
CUT OUTER TRIM CABLES TO LENGTH
39
Assemble inner trim cable (20183) to trim control lever (8248) as shown
below. Do not tighten fully at this point. Note the orientation of the lever from
the drawing below.
A
LEVER (8248)
BOLT (16947)
NUT (3089)
A
CABLE (20183)
A
WASHER
(6813)
INSERT
(16950)
INSERT (8947)
INSERT (17083)
B
NUT (3070)
Slide two of insert (8947) and one of insert
(17083) onto the trim lever pivot bolt (already
fitted in the left hand flap lever gate). Feed the
inner cable through the appropriate outer cable
I.E. top inner cable through top outer cable, the
top inner cable must exit the top outer cable at
the rear of the aircraft. Fit lever onto pivot bolt
followed by fibre washer (7586), washer 6.4
(6814) and nut (3070). Adjust the nut to give a
friction of approximately 2 kg (measured at the
top of the lever after 30 movements over the full
range. Secure the nut with split pin (8530).
Make sure that an even amount of inner cable
is protruding from upper and lower outer cables
at the rear and tighten the two bolts to clamp
the cable to the trim control lever.
B
SPLIT PIN
(8530)
WASHER 6.4
(6814)
FIBRE WASHER
(7586)
40
MEASURING TRIM CONTROL LEVER FRICTION (2 KG)
Temporarily fit both seat pans using clecos, drill the three 3.2 mm holes as
shown for the control stick support brackets (support under the bracket whilst
drilling). This may have already been done at the factory.
B
37
15
15
DRILL 3.2 MM WHILST SUPPORTING CONTROL STICK MOUNTING
BRACKET FROM UNDERNEATH. FIT CLECOS AS EACH HOLE IS
DRILLED
41
Align one of the control stick back stops (8261) bag No 35 as shown in the
picture below, drill 3.2 mm and cleco in place (these holes will later be drilled
to 4mm). With the control sticks held back using a suitable bungee align the
second stop (8261) so that it is touching the control stick pivot bolt head. Drill
3.2 mm and cleco in place.
ALIGN FRONT OF STOP
PLATE WITH BEND IN
SEAT PAN AND CENTRED
ON STICK PIVOT BOLT
WITH STICK HELD BACK ALIGN
SECOND STOP AGAINST STICK PIVOT
BOLT HEAD, DRILL AND CLECO IN
PLACE
42
Whilst the stick is tied back against the back stops the elevator deflections
can be set and recorded,this should be 25° +/- 1°.Connect the pushrod to the
elevator horn using bolt 6 X 21 (2833) bag No 35, don’t fit the nut yet.the up
travel of the elevator is set by adjusting the rose joint in or out of the pushrod
(the distance from the end of the pushrod to the centre of the rose joint must
not exceed 40mm, if it does adjust the rose joint at the front of the other long
pushrod). Once set the lock nut on the rose joint can be tightened and marked
with red paint, then the bolt (2833) can be secured with washer, nut and split
pin as shown.
ADJUST THIS DISTANCE( NOT GREATER
THAN 40 MM) TO SET ELEVATOR UP
TRAVEL TO 25°+/- 1°
SCREW
6 X 21
(2833)
NUT (3062)
SPLIT PIN
(8530)
WASHER 6.4
(66302)
ELEVATOR DOWN
STOP ADJUSTER
Now release the bungee holding the sticks back and set the down elevator
deflection to 20° +/- 1° by adjusting the stop underneath the control lever
housing.
43
Temporarily fit the flap/trim lever cover between the seat pans, use clecos or
M4 screws from bag No 2. fit the trim lever knob (2367) using screw (1896)
bag No 37.Connect trim cables to the elevator trim tab control horns as in the
following pictures (all parts from Bag No 37). With the trim control lever in the
fully aft position pull the cables taught and with the tab 25° down from the
level position (level with the chord line of the elevator) tighten the nuts to
clamp the cables. Check the fully up position by moving the control lever fully
forward until the knob contacts the flap/trim lever cover and measuring the
upward deflection of the tab. The deflection limits are: down 25°+/- 5°and up
5°+/- 3°, adjust the cables to achieve this.
KNOB (2367)
SCREW (1869)
FLAP/TRIM LEVER COVER TEMPORARILY INSTALLED
TO ALLOW SETING OF TRIM DEFLECTIONS
HEAT SHRINK
TUBE
TRIM CONTROL
CABLE (20183)
A
A
WASHER
(12044)
BOLT
(9628)
Slide heat shrink tube
(fitted earlier) over the
end adjuster and shrink
with hot air gun.
Solder socket (20326) to
exposed ends of inner
cable and cut off excess
cable.
NUT (3089)
WASHER (6813)
COUPLING PLATE (9741)
SPLIT PIN
(8530)
PIN (9635)
SOCKET (20326)
44
Remove the trim control knob and flap/trim lever cover. Position the front
portion of the cover and drill 3.2mm. This will be riveted in position later.
POSITION AND DRILL 3.2 MM BUT DO NOT RIVET IN PLACE AT THIS POINT
Whilst the seat pans are still in place position seat backs (8693 BAG 50) on
the lip of the rear seat pan flange and 82 mm in from the inner edge of the
cockpit side (check the seat backs stick up above the rear shelf approximately
130 mm), drill through pre made holes in seat back and cleco in place.
Remove the seat backs and open the holes in th fuselage out to 6mm and
install the rivnuts (6980).Open the holes in seat backs (8693) to 4mm.
130 mm
82 mm
RIVNUT (6980)
45
Remove seat pans, seat backs etc, open up the holes in the control stick back
stops to 4MM, also open up the holes in the spar and the seat pans to 4MM
where the back stops fit.De-burr all holes and vacuum out any swarf from the
fuselage.
OPEN THESE HOLES TO 4MM AND
DE-BURR ALL HOLES
OPEN HOLES IN STOP AND
SEAT PANS TO 4 MM AND
DE-BURR
Now apply emfimastic and rivet in place the tail fairing (E1 01-09 01), use rivet
3.2 X 7.9 (6472) from bag No 2. Clean off any excess emfimastic with
methylated spirits before it dries. The four upper most rivets can be pulled by
flexing the tailplane fairing as shown below.
46
The tailplane fairing can now be secured with screws M4 X 16 (51656) placing
a plastic washer (56125) on each one before fitting. Bag No 24.
SECURE TAILPLANE FAIRING
WITH SCREW M4 x 16 (51656)
WITH WASHER (56125)
UNDER EACH ONE
Fuel tank and fuel lines to firewall (bag No 46)
Cut and stick, using contact adhesive, the rubber sheet (13476) in the
locations shown below.
110 MM
620 MM
47
Also stick rubber sheet (13476) to fuel tank as shown below.
13893 RUBBER SHEET BOTH SIDES
Stick rubber strip (13893) along the surfaces shown in the pictures below.
This rubber is a little thicker than the rubber sheet so as to make up the
difference in levels between gussets ETC.
RUBBER STRIP
(13893)
Whilst you have the glue out stick the rubber sheet (13476) from bag No 66 to
the oil tank mount on the firewall.
RUBBER SHEET (13476) FROM BAG 66
48
Fit fuel level sender (9690) bag 47 to tank with gasket (7902), screws M5 X 25
(1841) and washers (44870), the operating arm will need bending as shown in
the picture, the aim is, when fitted the float can be made to touch both the
bottom and the top of the tank by turning the tank over.
GASKET (7902)
LEVEL SENDER (9690)
SCREW M5 X 25 (1841) AND
WASHERS (44870)
INSERTING SENDER INTO TANK WITH
GASKET AFTER BENDING ARM (THIS MAY
TAKE A FEW ATTEMPTS TO GET RIGHT)
Fit fuel outlet to bottom of tank (bag 47). Apply loctite 648 to the contact faces
and tighten with outlet pointing forwards.
SEALING WASHER (3474)
ADAPTED BOLT (30607)
ADJUSTABLE FITTING (3382)
Fit sleeve (7268) and
nut (3340) from bag
46 to the outlet and
lockwire the complete
assembly.
NUT (3340)
SLEEVE (7268)
49
Attach the fuel tank bonding straps (3530) to the tank using screws (11558)
bag 46. Cut a 330 mm long piece of fuel hose (7578) and attach it to the drain
sump outlet with cobra clamp 12/8 (7838).
SCREW (11558)
FUEL HOSE (7578)
330 MM LONG
COBRA CLAMP
12/8 (7838)
BONDING STRAP (3530)
Attach a 1270 MM long piece of fuel hose (7578) to the fuel feed outlet and
secure with cobra clamp 12/8 (7838). Cut a piece of fuel hose (7578) 80MM
long and slide on to the fuel return connection (top left of fuel tank) put a
couple of cobra clamp 11/7 (3740) on the pipe but do not secure at this point.
FUEL HOSE (7578)
1270 MM LONG
FUEL HOSE (7578)
80 MM LONG
COBRA CLAMP
11/7 (3740)
COBRA CLAMP
12/8 (7838)
Fit a 600MM long piece of transparent fuel hose (7254) using cobra clamp 9/7
(3738) to the tank vent connection on the top right of the tank (adjacent to the
filler neck).
COBRA CLAMP 9/7 (3738)
TRANSPARENT FUEL HOSE (7254) 600 MM LONG
50
Assemble the tank restraunt cables (9260), nut (52041),and turnbuckle
(8235). Only screw these together a couple of turns. Cut two pieces of
transparent fuel hose (7254) 180 MM long and slide over the cables.Fit the
barrel nuts (8247) into position in the straps on the back of the seat back
bulkhead.fit cable assemblies into the barrel nuts, NOTE THESE ARE LEFT
HAND THREAD. Hook the cable sover the bulkhead out of the way.
TRANSPARENT FUEL HOSE (7254)
180 MM LONG
CABLE (9260)
NUT (52041)
TURNBUCKLE
(8235)
BARREL NUT (8247)
If you have fitted the filler neck adaptor remove it by undoing the six screws
securing it.
51
Lower tank into position, feed fuel drain pipe through the hole in the rear spar
and the feed pipe forward through the hole in the crossmember alongside the
elevator pushrod.it can make it easier to fit the tank if the control sticks are
pulled fully aft as this moves the two armed lever out of the way. Push the
tank fully forward and as far to the port side as possible, this makes fitting the
filler pipe esaier.Fit filler pipe (5205) along with clamps (3496) onto the tank
filler neck, now push the tank as far to the starboard side as possible to bring
the filler pipe up against the filler assemblt on the fuselage side. Re-fit the filler
neck sliding it into the filler pipe (do not tighten the hose clamps yet). Fit bolts
6 X 20 (11557) with washers (6813) through holes in tank support brackets
with the thread facing outwards. Fit nicopress sleeve (8256) and a short piece
of heatshrink tubing onto the tank restraint cables, loop the cable back
through the nicopress sleeve .With split eye (8054) fitted onto the bolts loop
the cable around it and pull taught, slide the nicopress sleeve fully down to the
split eye and make a mark across the cables with a permanent marker.
Remove the cable, line up the marks with the nocopress sleeve up against the
split eye and crimp using the correct tool.Cut off excess cable and covet cut
end with tape or heatshrink tube. Repeat for the second cable. Both cables
can now be fitted to their respective bolts and secured with washer (7901) and
nut (3089). Now adjust the tension of the cables using the turn buckles and
lock them with the lock nuts.
WHILST LOWERING THE TANK INTO
POSITION FEED THE DRAIN PIPE
THROUGH THE HOLE IN THE REAR
SPAR
52052
CLAMP (3496)
RUN THE FEED PIPE THROUGHT THE
HOLE ALONGSIDE THE ELEVATOR
PUSHROD
Fit fuel filler pipe and push
tank over towards filler as far
as it will go. Re-fit filler neck,
sliding it into the filler hose
and securing with M4
screws.
Do not tighten clamps (3496)
until tank is secured by the
cables.
52
ALIGN MARKS AND CRIMP USING THE
CORRECT TOOL
COMPLETED NICOPRESS CRIMP
SPLIT EYE (8054)
NICOPRESS SLEEVE (8256)
WASHER (7901)
NUT (3089)
BOLT 6 X 20
(11557)
WASHER
(6813)
HEATSHRINK SLEEVE OR TAPE
TENSION CABLES USING TURNBUCKLE AND
THEN LOCK WITH LOCK NUT
COMPLETED TANK CABLE
53
ONCE THE TANK IS SECURE
POSITION AND TIGHTEN THE
CLAMPS ON THE FUEL FILLER
SECURE TANK BONDING STRAPS
WITH RIVETS (8493)
Feed the vent pipe from the top right of the tank down and through the front
one of the two grommets in the fuselage floor, secure to the side of the tank
using self adhesive clamp (51253) and cable tie (13393). Connect the fuel
drain pipe to the drain tap and secure with Cobra clamp12/8 (7838) , secure
the pipe to the rear spar web to prevent chafing using self adhesive clamp
(51253) and cable tie (13393).
VENT PIPE ROUTING
COBRA
CLAMP 12/8
(7838)
SELF ADHESIVE
CLAMP (51253)
& CABLE TIE
(13393)
SELF ADHESIVE
CLAMP (51253)
& CABLE TIE
(13393)
DRAIN PIPE ROUTING
The fuel feed line should be routed as shown in the following pictures and
secured with P clips.Drill 4MM holes , de-burr before fitting screws.
1
2
3
54
FUEL PIPE THROUGH CROSSMEMBER
POSITION 1
P CLAMP (55744)
SCREW 4 X 12
(49878)
SCREW 4 X 10
(50482)
WASHER
(6812)
NUT (8495) & WASHER
(6812) TO SECURE
SCREW (49878)
NUT (8495)
USE AT POSITIONS 1, 2 AND 3
FUEL PIPE THROUGH MAIN SPAR AND
UNDERCARRIAGE WEB (POSITION 2 & 3)
WRAP A PIECE OF FABRIC TAPE
(3965) AROUND FUEL PIPE AT EACH
P CLIP AND USE SPIRAL WRAP
(8543) WHERE NECESSARY
WASHER
(6812)
4
NUT (8495)
DRILL OUT RIVET AT POSITION SHOWN FOR M4 SCREW
4
COBRA
CLAMP 12/8
(7838)
SCREW 4 X 12
(49878)
P CLIP (3572)
55
Drill two holes in the firewall as shown in the picture below, both 10 mm
diameter, the top one is for the fuel return pipe and the bottom one is for the
fuel feed fitting. Fit grommet and “bushing” as shown in drawing below.
GROMMET (3784)
FUEL RETURN
PIPE (2154)
WASHER (48284)
PIPE FROM
ELECTRIC
FUEL
PUMP
BUSHING (7255)
NUT (46020
Slide fuel return pipe(2154) through firewall and through the top hole in each
fuselage stiffener, fitting a grommet (3784) at each station, after passing
through the seat back bulkhead bend the pipe and gently bell out the end,
connect to the already fitted rubber hose using the two cobra clamps already
fitted loosely to the hose. Cut the excess from the front of the tube as shown
above and again gently bell out the end.
FUEL RETURN PIPE ROUTING
FUEL RETURN PIPE CONNECTION
AT FUEL TANK
56
If you are fitting the optional electric fuel pump (supplied as a separate kit by
Light Sport) to the firewall as shown in the following photos. Make up the
connecting fuel pipe (7578) from the fuel tap to the inlet on the electric pump,
this pipe has the fuel filter in it 150 mm from the fuel tap (do not use the
Evektor supplied fuel filter, a Light Sport supplied “SKY 28” with your kit
should be used) use cobra clamp 12/8 (7838) at the connections. Connect
another piece of fuel hose (7578) to join the outlet from the pump to the fitting
on the firewall.If you are not fitting an electric pump, connect a piece of pipe
(7578) from the filter directly to the firewall fitting using clamps 12/8 (7838)
ELECTRIC FUEL PUMP WITH MOUNTING
BOLTS FROM LIGHT SPORT SUPPLIED KIT
SKY 28 FUEL
FILTER
150MM
COBRA CLAMP 12/8 (7838)
FUEL HOSE (7578) USED THROUOUGHT
57
From the Light Sport electric kit make up the wiring for the fuel level sender as
below. Do not fit the crimp connectors to the gauge end until the instrument
panel is fitted.
Fuel level sender wiring loom (Yellow 0.5mm², Black 0.5mm², Blue 0.5mm²)
2270
Blue terminal
on gauge
Blue terminal
on sender
Wires twisted together
Black terminal
on gauge
Black terminal
on sender
Yellow terminal
on gauge
150-300
Yellow terminal
on sender
Heat shrink sleeve 35 mm long
Over all crimp connectors and
at end of twisted section
150-300
NOTE YELLOW AND BLUE WIRES REVERSED AT GAUGE
Route the fuel sender wiring as in the pictures below fitting grommets (152337) from electrical kit in each fuselage stiffener. Secure to fuel return pipe
with small cable ties (04-0450).
Grommets (152-337)
FUEL LEVELSENDER WIRING AT
FUEL TANK SENDER
ROUTING OF FUEL LEVEL SENDER
WIRING
At this point we fit the radio antenna and route the coax through to the
instrument panel area. The antenna can either be fitted as shown, in the lower
fuselage skin, or in the rear turtle deck fitted through the reinforcement
triangle just rearwards of the rear transparency.
58
FLOOR MOUNTED LYNX VHF ANTENNA
TURTLE DECK MOUNTED LYNX VHF ANTENNA
ROUTE COAX THROUGH FUSELAGE STIFFENERS USING GROMMET (152-337) AND CABLE TIES (040450) WHERE NECESSARY
Lift the fuselage and support in suitable
trestles, one under the main spar and one
under the rear skid. At least three people
are required for this, two for the lifting and
one to position the trestles.
Main undercarriage (bag 42)
Glue rubber sheet (13476) to yokes (8670) and plates (9604). Fit the yokes
(8670) to the fuselage with pin (8499). Pin (8499) is fitted from the rear; at this
point do not fully tighten at this time.
59
Slide the main undercarriage leg into position and into inboard fitting (NOTE
THE LEGS ARE HANDED, THE FLAT FACE AT THE BOTTOM OF THE
LEG NEAR THE AXLE FACES REARWARDS) loosely fit plate (9604) with
washer (6814) and castle nut (3071) onto yoke to hold leg.
RUBBER SHEET
(13476)
PIN
(8499)
YOKE (8670)
MAIN UNDERCARRIAGE LEG
SPLIT PIN
(37002)
PLATE (9604)
WASHER
(6814)
CASTLE NUT
(3071)
Make sure the leg is pushed fully into the inboard fixing and position the
inboard end so there is a 8mm gap between the rear of the leg and the
fuselage cross member. An 8 mm drill shank is perfect for setting this gap; we
use a large clamp to hold the leg in position for drilling.
SET GAP BETWEEN REAR OF LEG AND CROSS MEMBER TO
8MM
8
60
Drill through the rear pilot hole 4MM, then 6MM and finally 7.5 MM (use a set
square to visually maintain the drill vertically whilst drilling). Now ream the
hole to 8MM and temporarily fit bolt (6814). Repeat for the front hole and then
remove the leg, de-burr the holes and vacuum out any swarf. The leg can now
be fitted using bolts (9616), washers (6814) and nuts (7810). We find the
easiest way of fitting the nuts underneath the inner leg attachment is to super
glue the washer to the nut then using the ring end of a 13mm combination
spanner it can be positioned and tightened. The outer leg attachment (plate
9604) can now be tightened, tighten nuts (3071) to evenly clamp the leg and
create a 1mm bow in the plate. Secure the nuts with split pin (37002). Finally
tighten pin (61177) and secure with lockwire. Repeat for other side and then
glue Gap seal (14464) over the hole in the fuselage floor. Seal around the
remainder of the leg with Emfimastic
NUT (7810) AND WASHER (6814)
GLUED TOGETHER
DRILLING MAIN
U/C FIXINGS
BOLT (9616)
USING 13 MM COMBINATION SPANNER
TO POSITION NUT AND WASHER
WASHER
(6814)
NUT
(7810)
PLATE (9604)
USE CONTACT ADHESIVE TO ATTACH
GAP SEAL (14464) TO SEAL OPENING
IN FUSELAGE FLOOR
NUT (3071), WASHER (6814)
& SPLIT PIN (37002)
61
WHEN FINALLY TIGHTENED SECIRE PIN WITH
LOCKWIRE
SEAL AROUND THE
REMAINDER OF THE
UNDERCARRIAGE LEGS
WITH EMFIMASTIC. IT IS
BEST TO MASK THE
AREA WITH TAPE FIRST,
APPLY THE EMFIMASTIC
AND THEN SMOOTH OUT
WITH A FINGER WETTED
WITH WASHING UP
LIQUID. REMOVE ANY
MASKING TAPE BEFORE
THE EMFIMASTIC DRIES.
Whilst you have the Emfimastic out it is a good time to mount the wing root
lower fairing brackets. On the underside of the fuselage just aft of the flap
torque tube is an area with no rivets, position the brackets (12751) bag 17,
mark for 3 X 3.2 mm holes to follow the rivet pattern already there. Drill the
brackets, position on fuselage, drill and cleco in place. Remove the brackets,
de-burr holes and apply Emfimastic to the contact area. Rivet in place using
the six 3.2 X7.9 rivets (6472) from bag No 17.
BRACKET (12751)
AREA ON UNDERSIDE AFT OF FLAP
TORQUE TUBE FOR FITTING
BRACKETS (12751)
RIVET 3.2 X 7.9 (6472)
Also mask and fill with Emfimastic around the rear spar attachment (if you
don’t fill this gap it creates a draught up under the seat).
62
Main wheels and brake assemblies (bag 42)
The main wheels come already assembled with the brake disc and calliper on
them. They may be only loosely assembled and the lock tabs not bent over.
We prefer to disassemble the disc from the wheel so to be able to grease the
brake pad pins. Don’t lose the spacer tube between the brake calliper plate
and the wheel bearing when the temporary lockwire is removed. If the lock
tabs have not been bent over the long tag will need cutting shorter to prevent
it digging into the tyre when it is bent over the wheel rim. Alternately you can
just check that the bolts securing the disc to the wheel is tight and secured
with a lock tab and then apply grease to the two pins which secure the brake
pads (use a small screwdriver to spread the grease on the pins).
Grease the wheel axles and the brake calliper mounting plate anti rotation
pins and slide the wheel onto the axle, check that the calliper anti rotation
plate fully engages on it’s pins and then secure with washer (7744), nut
(36555) and split pin (51879). A different nut is used if wheel spats are to be
fitted and this is detailed in the drawing with the wheel spat kit.
IF REQUIRED CUT LOCK TAB TO
PREVENT IT DIGGING INTO TYRE WHEN
BENT OVER WHEEL RIM
ENGAGING BRAKE CALLIPER PLATE WITH
ANTI ROTATION PINS
DISC SECURING BOLT LOCK TAB
WASHER (7744)
SPLIT PIN
(51879)
NUT (36555)
The trestle under the main spar can now be removed and the fuselage
lowered to sit on its main wheels.
63
Drilling firewall for engine accessories
The picture below shows the positions we drilled holes for fitting of engine
accessories to the firewall. This task could be left until later in the build but we
like to get all drilling on the firewall done before fitting the nose leg ETC.
DRILL 2 X 5MM DIA. FOR
RECTIFIER REGULATOR
DRILL 2 X 4MM DIA
FOR CAPACITOR
94
DRILL 2 X 4 MM
DIA. FOR
COOLANT BOTTLE
150
170
65
80
230
40
40
DRILL 19MM DIA. FIT
GROMMET 152-345
100
70
40
110
175
200
49
340
50
DRILL 2 X 6MM
DIA. FOR CHOKE
CABLE FITTINGS
DRILL 2 X 4MM DIA.
FOR STARTER
SOLENOID
64
Cowling fasteners (Bag no 63)
As the cowling has been pre fitted at the factory and pilot holes made, the
fitting of the fasteners to both the cowling and the firewall flange can be done
without the need for the engine to be fitted. This also means that ant swarf
created during this procedure will not get into places and components you
don’t want it to.
Open the holes around the firewall flange to 3.2 mm and cleco in place the 10
plate nuts for securing the lower cowling (4 down each side and one each
side in the brackets at the bottom of the firewall). Drill through the fixing holes
in the nut plates 3.2 mm and then remove the nut plates. Now drill the centre
hole of each fixing point to 4mm, countersink the two outer holes of each
fixing point. Using rivets 3.2 X 9.5 (6796) fix the nut plates to the inner edge of
the firewall flange.
4MM DIA.
CLECO NUT PLATES IN PLACE AND
DRILL THROUGH FIXING HOLES 3.2MM
3.2 MM DIA. THEN
COUNTERSINK TO
SUIT RIVET
NUT PLATE
RIVET 3.2 X 9.5
(6796)
65
Drill the top three holes in the firewall flange to 5.5 mm, now using the 5.5 mm
drill bit inserted through a camlock receptacle align and drill the two fixing
holes 3.2mm. Open the 5.5 mm holes in the firewall flange to 14mm (we use a
stepped drill for this) and de-burr the edges. Countersink the 3.2 mm holes to
accept rivet (6796). Before riveting in place the camlock receptacles it may be
necessary to file/grind a little from the edge that will be up against the curve of
the firewall flange to get a satisfactory fit. Rivet the three receptacles in place
with rivets 3.2 X 9.5 (6796).
USE A 5.5 MM DRILL BIT TO
ALIGN CAMLOCK RECEPTACLES
WHILST DRILLING FIXING HOLES
GRIND/FILE EDGE OF
CAMLOCK RECEPTACLE TO
ACHIEVE SATISFACTORY
FITTING
RIVET IN PLACE WITH 3.2 X 9.5 COUNTERSUNK RIVETS (6796)
66
Cleco the upper and lower cowling halves together, the pre drilled holes may
need opening up to suit the size of clecos used.The holes around the rear of
the lower cowling will need drilling to 4mm for the cowling fixing screws.
Assemble the camlock fastener rings to the locking pins as shown in the
pictures below.
Remove one cleco at a time and drill 12mm through both cowling halves,
again we use a stepped drill for this. Fit assempled camlock through hole and
secure into receptacle. Once all clecos have been replaced with camlocks
mark the position from inside the cowlings for the receptacle securing rivets.
Remove the camlocks and separate the two cowling halves. Using M4 screws
from Bag 63 temporarily fit the lower cowling to the fuselage, drill 3.2 mm and
countersink the holes for riveting the camlock fastener receptacles to the
lower cowling half, before riveting these on open each of the 12mm DIA. holes
out to 14mm DIA.Fit the camlock assemblies into the top cowling and secure
with the locking rings.
12 MM DIA.
COWLS CLECO’D TOGETHER
67
MARKING POSITION OF SECURING
RIVETS
LOCKING RING
RIVET 3.2 X 9.5 (6796)
14MM DIA.
Coolant radiator (mounting to cowling) Bag 65
Whilst the cowling is temporarily on the fuselage the coolant radiator can be
mounted. The radiator is supplied separately from Light Sport. All the parts for
this operation can be found in bag No 65.
Assemble the holders 9948 (top) and 9949 (bottom) to the radiator as shown
below (there was some confusion as to which is the top and bottom holders
so when trial fitting to cowling see which way fits best).
A
ROTAX RADIATOR
995697
68
HOLDER 9949 / 9948
SCREW 57082
WASHER 6.4 (7901)
SPACER TUBE (7568)
WASHER 10.5 (48284)
Do not fully tighten the bolts securing the holders yet. Trial fit into cowling and
adjust holders to get best fit, the radiator needs to be as far over to the port
side without the starboard side header tank showing in the cowling opening.
Once the holders are in the correct place tighten the bolts and secure with
lock wire. Glue rubber pad (43287) to the holders at each screw fitting
location.
RUBBER PAD (43287)
RADIATOR BOLT LOCKWIRED
From the optional heating kit find the radiator air scoop and 4 off 3.2 x 7.9
(6472), this has to be aligned to the radiator, drilled and riveted in place. Note
the position of the scoop, as the radiator has to be offset for clearance of
coolant pipes the scoop should also offset to bring it back to centre reference
to the cowling aperture.
RIVET 3.2 X 7.9
(6472)
69
Align Completed radiator assembly in cowling, remember it must be as far to
port as it can go without the starboard side header tank showing in the
cowling aperture. Mark and drill 4mm the holes to secure it to the cowling.
Using screw M4 X 16 (51656) and plastic washer 3.7 (56125) secure the
assembly to the cowling. The cowling can now be removed from the fuselage.
Glue leatherette strip (6698) around the firewall flange and cut holes where it
covers the fastening holes.
Nose leg and wheel (Bag No 40)
The nose leg lower bearing is loosely attached to the lower firewall and has
the bearing already glued into it. It is worth having a trial assembly of the leg
into the bearings to make sure it moves freely, use some plain M6 nuts on the
bolts during this trial assembly. Once happy with the fit the leg can be finally
fitted with the rubber stop (12134) in the top of the leg and the lower bearing
assembly can be tightened using the supplied stiff nuts. Grease the bearing
surfaces before fitting.
RUBBER STOP (12134)
NOSE LEG
USING
RATCHET
STRAP TO
COMPRESS
RUBBER
STOP
Use a ratchet strap between the bottom of the leg and the lower bearing
housing to push the leg upwards and compress the rubber and then insert the
“rubber washer” 12383 and seat it onto the lower bearing housing. Fit tube
10608, rollers 12243 and circlips 3750 into position and then release the
ratchet strap.
INSERTING RUBBER WASHER (12383)
RUBBER WASHER SEATED ON LOWER
BEARING CARRIER
70
ROLLER (12243)
TUBE (10608)
CIRCLIP (3750)
Once the ratchet strap is
released and the rollers are in
contact with the rubber pad
check for free movement.
The nose leg suspension shock cords (37195) are already made up and only
require doubling up before fitting into position, follow the sequence below to fit
and tension the shock cords.
Double up the shock cords and fit
in position behind the nose leg,
one each side, with the knot at the
top and against the leg. Try to get
the crossover in the doubled up
shock cord towards the back.
71
Slide tube (10612) through holes in lower nose leg bracket, passing it through
both loops of both shock cords. Secure tube with split pins (12291).
SPLIT PIN (12291)
TUBE (10612)
Working on one shock cord at a time, pass a length of cord through the loop
without a knot in it. Pull the loop with the knot up and hook it over the lug on
the nose leg, using the cord pull the second loop up and over the lug. Repeat
for the other shock cord. Finally secure the shock cord ends to the leg with
two cable ties (9754)
CABLE TIE
(9754)
72
The nose leg gaiter (14345) is a little too long as supplied in the kit so we cut
three “ridges” off from the top of it. Lubricate the leg/gaiterwith WD40 or
similar and slide the gaiter up from the bottom. Be careful not to split the
gaiter stretching it over the bracket for the nose wheel spat. Evektor supply
clamp (3494) to secure the gaitet to the leg but we prefer to use cable tie
(9754) as it is neater and saves a bit of weight.
CUT THREE “RIDGES FROM THE TOP OF
THE GAITER (14345)
LUBRICATE LEG AND GAITER TO
EASE FITTING
BE CAREFUL NOT TO SPLIT THE GAITER
WHEN STRETCHING IT OVER THE WHEEL
SPAT FIXING LUG
CABLE TIE (9754)
OR CLAMP (3494)
Fit nose wheel axle (11601) and the distance washer (10610), note that the
cupped side of the washer goes towards the leg. Fit nose wheel assembly
(10648) and secure with washer (7744), nut (7013) and split pin (51879). If
fitting wheel spats a different nut will be used (see instructions included with
the spats).
AXLE (11601)
DISTANCE WASHER (10610)
NOTE CUPPED SIDE
TOWARDS LEG
SPLIT PIN
(51879)
NOSE WHEEL
ASSEMBLY
(10648)
WASHER (7744)
NUT (7013)
73
Rudder pedals (Bag No 36)
Assemble four off pedal attachment (8388), bronze bearing (8384), bolt
(66527), washer (6813) and nut (3089). Put a spot of loctite 648 between
pedal attachment and bronze bearing. Fit two of the assembled rudder pedal
bearings to the outer fuselage attachment points using screw M5 X 16
(43233).
WASHER
(6813)
BEARING
(8384)
NUT
(3089)
ATTACHMENT
(8388)
BOLT
(66527)
APPLY LOCTITE 648 HERE
SCREW M 5 X 16 (43233)
74
The holes for the centre rudder pedal bearing fixings now need to be marked
and drilled. To do this first put masking tape along the two centre rivet lines
and mark a centre line for each pedal attachment, this line will be the centre
line for the pedal bearings and for the rivets in the two doubler plates. Fit the
rudder pedals , right hand pedal (11104) left hand pedal (11078) to the
installed outer bearings and install the inner bearings to their other ends.
Check that both ends are fully seated on the bearings and check the centre
line marked can be seen through the holes in the inner attachment. We have
to sometimes shorten the right hand pedal cross tube to get these to align, if
this is the case cut only from the inner end. Set the pedals so the cross tubes
connecting the rudder pedals are parallel to the firewall i.e.inner and outer
pivot points same distance from firewall, mark and drill 5 MM diameter for the
pedal fixing bolts.
MARK CENTRE LINES FOR INNER
RUDDER PEDAL BEARING
ATTACHMENT.
CENTRE LINE VISIBLE THROUGH
HOLES IN BRACKET
IF REQUIRED CUT A LITTLE FROM
THE PEDAL TO GET CORRECT
ALIGHNMENT OF THE BEARINGS
DRILL THROUGH
BRACKETS 5MM DIA.
SET PEDALS PARALLEL TO THE
FIREWALL
Remove pedals and brackets and, using
the fixing bolts (43233), align the two
doubler plates (8214). Mark a centre line
on the plates and mark out for five 3.2 mm
holes in each plate. Use similar spacing for
the rivet holes to the already fitted rivets.
We have also found that there can be
quite a gap between the end of the plates
and the next rivet, if this is the case drill
and fit 3.2 X 7.9 rivet equidistance
between the two
75
DOUBLER PLATES
RIVETTED IN PLACE
DOUBLER PLATES (8214) DRILLED
AND CLECOED IN PLACE
FIT ADDITIONAL
3.2 X 7.9 RIVETS
HERE IF
REQUIRED
RIVET 3.2 X 11.7(6793)
FITTED FROM
UNDERSIDE
Apply Emfimastic to contact face of doubler plates and cleco in place, remove
one cleco at a time and from underneath rivet in place using 3.2 X 11.5 rivet
(6793). If necessary fit the additional 3.2 X 7.9 rivet as shown.
Assemble brake pedals (9053) to rudder pedals securing with rings (8279)
and split pins (3702). A 2mm hole for the split pin will need drilling through the
ring and brake pedal whilst they are assembled to the rudder pedals, de0burr
holes and grease pedals before final assembly.
BRAKE PEDAL (9053)
SPLIT PIN (3702)
RING (8279)
LEFT HAND RUDDER PEDAL
(11078)
RIGHT HAND RUDDER PEDAL
(11104)
76
Brake master cylinders Bag 44
Assemble as per drawing below, note the threaded portion of the master
cylinder pishrod will probably need shortening to achieve correct pedal
alignment. Leave final adjustment until the pedals are fitted and set up in the
aircraft.The “angular connection” (11041) requires fitting with loctite 648 to
glue it in position as they cannot be tightened fully.
MASTER
CYLINDER
(9006)
WASHER 5.3
(44870)
ANGULAR
CONNECTION (11041),
FIT WITH LOCTITE 648
PIN 5 X 20
(3008)
Left hand pedal assembly shown, right
hand pedal assembly requires angular
connection (11041) to be pointing
opposite way.
SPLIT PIN 1.6 X 12
(8530)
77
Assemble the rudder cable connection components (from bag No51) to the
outer ends of the pedal assemblies in readiness to make up the rudder cable
ends at a later stage (do not fit a split pin at this stage).
WASHER 8.4 (6814)
NUT (3071)
SPLIT EYE (8054)
BUSH (17972)
NUT (3071)
WASHER 8.4 (6814)
Grease the bearings and assemble the completed rudder pedals into the
fuselage. Secure the inner bearing brackets through the floor as shown below.
SCREW M5 X 16
(43233)
WASHER
(44870)
NUT M5
(7494)
78
Using suitable props and bungees set the rudder pedals 235 mm from the
centreline of the pedal top tube to the firewall and level with each other.
235
Nose wheel steering rods (bag No 40)Fit push rods 12208 and 10646 to the
nose leg steering arms, note one pushrod is longer than the other one and
with the pedals set as described above it is obvious where they fit. It is
important to assemble the rods to the nose leg with the washers exactly as
shown in the picture below.
SCREW
62369
WASHER
31494
WASHER
66302
NUT
3062
SPLIT PIN
10894
Set the nose wheel in the straight-ahead position, we use a long metal
straight edge to gauge this, note that the whole nose leg is not on the centre
line of the fuselage. Now adjust both steering rods to length and fit to pedal
spigots using washer 66302 and nut 3062, we had to fit an additional washer
(6813) between the rod end and the pedal. Do not fully tighten the nuts or fit
the split pins (10894) at this point. Tighten the locknuts on the rose joints and
bend the lock tabs to secure.
WASHER 66302
NUT 3062
WASHER 6813
79
Rudder cable finishing
With the rudder pedals still locked loop the rudder cables around the split
eyes already fitted to the rudder pedals with the cable free end uppermost,
using a couple of ratchet straps and a spring balance attached to the free
ends and around the main spar pull equally on each cable to achieve the
required 25KG preload. Adjust each ratchet strap to centre the rudder whilst
maintaining 25KG (picture 1 & 2). When satisfied that all is correct slide the
nicopress sleeves up against the split eyes and mark across the cable and
free end where it exits the free end with a permanent marker (picture 3). Undo
the retaining nut remove the cables from the pedals, slide the nicopress
sleeve up to the split eye and align the marks and crimp the sleeve with the
correct tool. There are three crimps per sleeve and it is best to do the one
nearest the split eye first and work back (picture 4 & 5). Use a gauge to check
for satisfactory crimping (picture 6). Cut off the free end with about 10 mm
protruding from the sleeve, wrap a piece of fabric tape around the cable and
slide the already fitted heat shrink tube over and shrink (picture 7).
PICTURE 1
RIGHT HAND CABLE TENSIONED WITH RATCHET STRAP
PICTURE 2
LEFT HAND CABLE TENSIONED WITH STRAP, PUT
A SPRING BALANCE IN LINE WITH THE STRAP
AND ADJUST BOTH STRAPS TO CENTRE RUDDER
WHILST MAINTAINING 25 KG TENSION
80
PICTURE 3
MARK ACROSS
CABLES WITH
PERMANENT
MARKER, THEN
RELEASE
TENSION AND
REMOVE FROM
PEDALS
PICTURE 4
ALIGN MARKS AND
CRIMP NICOPRESS
SLEEVE
PICTURE 6
CHECKING WITH GAUGE
PICTURE 5
COMPLETED NICOPRESS SLEEVE
WRAP FABRIC TAPE AROUND THE
CABLES AND THEN SLIDE
ALREADY FITTED HEAT SHRINK
TUBING OVER AND SHRINK.
PICTURE 7
81
Grease the bearing surfaces and re-fit the cables to the rudder pedals (it is
easier to disconnect one of the steering rods from one of the pedals, fit the
cables and then re-fit the rod) secure the cables with nut 3071 and fit split pin
37002 (bag No 51)
BUSH (17972)
SPLIT EYE (8054)
SPLIT PIN 37002
NUT (3071)
WASHER 8.4 (6814)
Rudder stops
Before carrying out this step the rudder circuit should be completely
assembled and have the correct tension (25 KG). Deflect the rudder to the left
32°, check that the adjustable stops are set in the middle of their range and
position the rear left and front right adjustable stops against the stop plates.
Position the nicopress sleeves against the adjustable stops and carefully
insert the short lengths of cable (15683 Bag No 51) into the sleeves. Whilst
holding everything in position crimp the nicopress sleeves using the correct
tool. Repeat the procedure for the other stops and with the rudder set at 32°
to the right. Slide the pieces of heat shrink sleeve over all four nicopress
sleeves and over the first part of the adjustable stops, shrink this in place to
retain the stops against the nicopress sleeves. Fine adjustment of the rudder
deflections can now be made before locking the adjusters, deflections should
be 30°± 2°, we find that closer to the 32° gives a better turning circle on the
ground. Drill a 2.5 mm hole to secure the front guide tube to the vertical
fuselage stiffener with a small cable tie (13393 Bag No 40). Tighten and
secure with split pin (10894 bag No 40) the nuts holding the steering rods to
the rudder pedals. Cable tie the steering rod gaiters to the rods (we cut a little
off of these as we felt they were too long).
SHORT CABLE 15683)
82
CRIMPING RUDDER STOP NICOPRESS SLEEVES
COMPLETED RUDDER STOPS
SETTING RUDDER DEFLECTIONS
CABLE TIE (13393)
83
Brake pipes (bag No 44)
Make a small slit in the right hand aileron pushrod gaiter and feed right hand
brake pipe (11043) from the outside through it, feed the pipe through the hole
at the bottom of the vertical stiffener and fit grommet (37085). Feed pipe up to
master cylinder and connect to the angular connection (note, the olive goes
onto the pipe with the chamfered end facing into the nut). Using cable ties
(7531) secure the pipe to the rudder pedal cross tube. Fit some protective
spiral (8543) where it routes around the outer pedal pivot; connect the other
end of the pipe to the brake calliper. Using two of cable tie (9754) secure the
pipe to the rear of the undercarriage leg. Mark the positions of the rivnuts on
the fuselage sides for securing the pipes and drill 6mm diameter. The photos
below show the locations of the Rivnuts. Fit rivnuts (6980) and secure pipes
with “P” clip (57092), screw M4 X 12 (51655) and washer (6812), wrap a
piece of fabric tape around the pipe at each location and fit a piece of
protective spiral (8543) over the pipe from where it leaves the undercarriage
leg up to the first “P” clip. Repeat for the left hand side using pipe (11042).
Use Emfimastic to glue the pipes into the corners of the fuselage at a couple
of locations and in-between the cable ties on the rear of the undercarriage
legs.
GROMMET
(37085)
“P”CLIP (5709)
GLUE WITH
EMFIMASTIC
CABLE TIE
(7531)
84
PROTECTIVE
SPIRAL (8543)
EMFIMASTIC
RIGHT HAND SIDE
CABLE TIE
(9754)
FABRIC TAPE
PROTECTIVE
SPIRAL (8543)
“P”CLIP (57092),
WASHER (6812) AND
SCREW (51655)
LEFT HAND SIDE
85
Bleeding the brake system
The brake system on the EV97 can be bled one of two ways; either gravity
bled or using a syringe, pumped up from the calliper to the master cylinder.
Gravity bleeding
Unscrew the cap from the top of the cylinder to be bled and fill it with
automotive (dot 4) brake fluid, place a tray under the associated calliper and
loosen the bleed nipple. Fluid should gently run through under the force of
gravity, keep topping up the master cylinder (do not let it become empty)
Once fluid is seen to be exiting the bleed nipple without any air bubbles in it
close the nipple and check the pedal is free from sponginess (repeat if
necessary). Top up the master cylinder until the fluid is just level with the step
in the outer cylinder wall and re-fit the top cap. Finally clean of any spilt brake
fluid.
Bleeding using syringe
This is by far the best and quickest way to bleed the brakes, you will need a
medium sized syringe and a piece of tubing that fits snugly on both the
syringe and the bleed nipple.
Wrap a piece of rag around the master cylinder to be bled to catch any fluid
spills and unscrew the cap from the top of it. Fill the syringe with brake fluid
and attach using a suitable length of tube to the appropriate calliper bleed
nipple. Undo the bleed nipple approx ½ a turn and gently squeeze the syringe
to push the fluid up from the calliper to the master cylinder, keep an eye on
the master cylinder to make sure it does not overflow. When the fluid level in
the master cylinder reaches the step on the outer cylinder wall stop and
tighten the bleed nipple.
Re-fit the top cap to the master cylinder and check the pedal feels firm and
not spongy. Clean off any spilt brake fluid.
Master cylinder top removed and cylinder
wrapped with rag
Brake bleeding using syringe
86
It is now time to have the aircraft inspected and the work completed
signed off by your LAA inspector before continuing with the rest of the
build.
Once the above inspection is complete and your inspector is happy for you to
do so you can fit the rear turtle deck. Before fitting the panel though, put a few
drops of oil on all of the control linkages and have a good vacuum around.
Apply Emfimastic to the joint surfaces and cleco in place the side panels, rivet
in place with Rivet 3.2 X 7.9 (6472) from bag 2.
Mask around rear
canopy and apply
Emfimastic to
provide a seal,
smooth with a wet
finger and remove
masking tape before
the Emfimastic dries
Seat pans and stick back stops
The seat pans have Emfimastic applied only to the joint with the fuselage side
and between the doubler panel and the seat pan. Most rivets are 3.2 X7.9
(6472) from bag 2, the exceptions are, six rivets (three each side) which go
through the spar cap and secure the control stick mounting brackets which
are 3.2 X 11.2 (6793) bag 2, another four (two each side) of the 3.2 X 11.2
(6793) bag 160 which go at the inboard end of the row of rivets along the
base of the pan and at the front inner end. Rivet the stick backstops (8261) in
place using rivet 4 X 12.7 (6794) from bag No 35.
APPLY EMFIMASTIC AT THIS JOINT
RIVET 3.2 x7.9 (6472)
87
ALL RIVETS CIRCLED
ARE 3.2 x 7.9 (6472)
APPLY
EMFIMASTIC TO
THIS JOINT
RIVET 3.2 X 11.2
(6793)
RIVET 4 X 12.7 (6794)
BAG No 35
BACKSTOP (8261)
88
Flap lever cove and centre seatbelt fixing
Fit belt attachment screw (8371) bag 51 through the two centre seatbelt fixing
lugs, put a spot of loctite 648 at the contact points and centralize. Fit the four
M6 X16 screws (6818) from bag 160).
SCREW M6 X 16
(6818)
SCREW (8371)
Rivet the front piece of the flap lever cover (E1 02-05 21) in place using rivets
3.2 X 7.9 (6472) from bag 2.
RIVET COVER IN PLACE USING 3.2 X 7.9 (6472) RIVET
89
Glue and sew the gaiter (9059) from bag 36 to the flap lever cover, thread
(8548) is supplied for this. Note the orientation of the gaiter.
SEW THROUGH PRE MADE
HOLES USING THREAD
(8548)
GLUE GAITER (9059) TO HOUSING
WITH CONTACT ADHESIVE
Fit flap cover using screws M4 X 12 (51655) and plastic washer (56125) from
bag 160. fit trim lever knob (2367) using screw (1869) from bag 37.Slide foam
grip (7253) bag 36 onto flap lever.
KNOB (2367)
SCREW (1869)
FOAM GRIP (7253)
SCREW M4 X 12 (51655)
WASHER 3.7 (56125)
Fit trim and flap control placards to flap lever cover from the decal sheet.
Luggage shelf and baggage retaining bungee
Cut bungee (6355 ) bag No53 to 1850 mm and feed through holes, tying
knots at each outer endPlate nuts have already been fitted to the baggage
bay shelf mounting flange at the factory and holes already made in the shelf,
locate the holes in both the shelf and, using a small soldering iron, burn holes
in the fabric covering.Fit the shelf and secure with screw M4 X 12 (51655)
from bag 2. Stick the aluminium baggage placard (17507) in a visible location
using double sided tape.
90
Tie knot to
secure outer
ends after fitting
through holes
Feed through both middle holes
Seat back rests
Glue hook Velcro (66968) bag 53 onto the seat back rests (8693) to match the
position of the loop Velcro on the seat back cushions, Fit seat backs with
screws M4 X 16 (51656) from bag 50.
SEAT BACK
(8693)
SCREW M4 X 16
(51656)
HOOK VELCRO (66968)
91
Seat belts Bag No 51.
Fit seat belts as per pictures below.
REAR FIXING
OUTER FIXING
TUBE (14291)
WASHER
(7901)
BOLT
(8128)
NUT (3089)
STEPPED
COLLAR
(6983)
CENTRE FIXING
STEPPED COLLAR
(6983)
NUT (7494)
WASHER (44870)
92
Pitot and static lines (Light Sport instrument kit and Bag No 49)
Cut two 1000 mm long pieces of blue urethane pipe and two 300 mm long of
the clear pitot tube (6945), both from the Light Sport instrument kit, join the
blue and clear pipes together with the supplied straight joiners. Mark one pipe
STATIC and the other PITOT (the Evektor supplied stickers don’t stick very
well so we use a marker pen on the pipes).Install grommets (3787) from bag
no 49 in fuselage side stiffener and in the gusset behind the instrument
coaming. Push the clear end of the pipes through the slit in the aileron
pushrod gaiter where the brake hose passes through and feed the blue hoses
up through the grommets to rear of the instrument coaming.
CLEAR PITOT TUBE (6945)
LIGHT SPORT
INSTRUMENT KIT
¼” BLUE URETHANE PIPES 1000 MM
STRAIGHT JOINERS
GROMMETS (3787)
CLEAR PITOT TUBE (6945) 300 MM LONG
93
Interior trim, carpet and seat cushions
Glue hook velcro from bag 53 to the small tabs on the cockpit floor and up the
vertical stiffeners to align with the already fitted loop velcro on the cockpit side
panels. The side panels fit under the top longeron angle.
Glue hook Velcro to seat pans to align with loop Velcro on the bottom of the
seat cushions. Glue loop Velcro around the control stick cut out and fit the
control stick gaiters. Note we have not fitted the aluminium panel over the
controls to save a little weight, it is up to you whether you fit this or not. Glue a
couple of strips of hook Velcro the floor and fit the carpet. Fit the seat
cushions noting that these are handed.
HOOK VELCRO
LOOP VELCRO
Oil cooler fitting (Bag no 66 and Light Sport oil cooler kit)
94
Use loctite 648 on the threads of the oil cooler connection elbows. Fit the
cooler to the brackets on the lower firewall using the two large nuts supplied in
the oil cooler kit and two of silent block (7109) from bag No 66. Fit the two oil
pipes to the cooler using the clamps supplied with the oil cooler kit. The left
hand oil pipe is 470 mm long. The length of the right hand pipe is 620 mm
long if you are fitting a 90° elbow in the oil pump (elbow not supplied), if
however you do not intend to fit an elbow in the oil pump leave this pipe until
it’s length can be determined.
FIT ELBOWS WITH LOCTITE 648
SILENT BLOCK (7109)
OIL HOSE 620 MM
LONG ONLY IF
FITTING ELBOW AT
OIL PUMP, LEAVE OFF
UNTIL LATER IF
ELBOW NOT BEING
FITTED
OIL HOSE 470 MM
LONG
95
Battery and starter solenoid (Light Sport electrical kit and Rotax engine
accessories)
Fill battery with supplied acid and fit into carrier, tighten securing turnbuckle
and wire lock. We fitted th optional smaller battery to save weight and had to
add some packing. Fit the starter solenoid to the firewall with M4 X 12 screws,
washers and nyloc nuts supplied in the Light Sport electrical kit through the
holes already drilled.
WIRE LOCK
TURNBUCKLE
FIT SOLENOID USING M4 X 12 SCREWS,
WASHERS AND NYLOC NUTS
Rectifier/regulator and capacitor ( Light Sport electrical kit, rotax engine
accessories and bag 75)
Fit rectifier/regulator to firewall using M5 X 18 screw (7951), washers (44870),
spacer (7521) and M5 nut (7494). Fit earthing wire made from 130 mm long
black 2.5mm² wire with terminals 150-276 on each end under the right hand
fixing. Fit the capacitor using the supplied fittings, under one of the fixing nuts
on the back face of the firewall connect a 250 mm long black 1.5mm² wire
using terminal 150-270, this wire will become an earth supply to the rpm pick
up and should be routed through a grommet in the firewall as shown. Connect
the wire from the earth point on the rectifier/regulator to the negative side of
the capacitor.
WASHER 44870)
TERMINAL (150-276)
SCREW
(7951)
WIRE FROM REAR
OF CAPACITOR
NUT (7494)
SPACER
(7521)
96
Wire from rear of capacitor mounting bolt.
Black heat shrink sleeve
35 mm long
Capacitor
mounting bolt
250
black 1.5mm²
150-270
Wire from rectifier/regulator earth point to capacitor negative terminal.
Black heat shrink sleeve
35 mm long
- terminal on
capacitor
Rect/reg bolt
130
150-276
Black 2.5 mm²
Coolant overflow bottle bracket ( Bag No 65)
Mount the coolant overflow bottle bracket (7866) to the firewall using screws
M4 X 8 (57924), washers (6812) and nuts (8495) through the holes already
drilled.
BRACKET (7866)
SCREW (57924)
WASHER (6812)
NUT (8495)
BRACKET (7866)
SCREW (57924)
NUT (8495)
WASHER (6812)
97
Engine mounting frame
Before fitting the engine mounting frame to the firewall carefully sand off the
powder coating from the faces that will contact the engine and from the two
points where the bonding cables attach. Bag no 68 contains all of the
mounting rubbers and spacers etc. The fixing bolts (47633) can be found in
bag No 62. manouvre the frame under the nose wheel and up into position,
secure to firewall and torque the bolts to 23NM. Position, mark, drill and rivet
brackets (18406) into position with rivets 3.2 X 7.6 (6472) and lockwire from
the hole in the brackets to the pre-drilled holes in the bolt head. Bolts (47633)
are wire locked to the tangs on the engine frame and the two bonding straps
are fixed using M4 X 12 button headed allen caps ( for some reason these
have never been supplied in the kit). Mark all bolt heads with a line of paint to
aid future inspection.
WASHER
(7267)
SILENT BLOCK
(7244)
TUBE
(7288)
CUP (7280)
SILENTBLOCK
(7244)
BOLT (47633)
CUP (7280)
SILENTBLOCK
(7244)
CUP
(7280)
WASHER
(7267)
CUP
(7280)
BOLT (47633)
TUBE
(7288)
98
CLEAN OFF POWDER COATING ON
CONTACT FACES BEFORE FITTING
ENGINE FRAME
MOUNTING, NOTE
POSITION OF
WASHER (7267)
M4 X 12 BUTTON HEADED
ALLEN SCREW TO ATTACH
BONDING STRAP
WIRE LOCK BOLT
TO TANG ON
ENGINE FRAME
99
Installing engine
Before installing the engine, remove the carburettors, the transport brackets
and the top R/H M10 bolt. Disconnect the lower coolant hoses from the water
pump and turn the main inlet to face towards cylinders 1 and 3. The
waterpump outlet pipes may need rotating to give better clearance between
the engine frame and the coolant hoses, if this is necessary use a hot air gun
to soften the loctite holding the pipes and be very careful not to damage the
very soft aluminium tubes (we use a 3/8” socket extension bar inserted into
the tubes). Fit a 600 MM long piece of oil hose on to the oil return outlet on
the bottom of the crankcase using the supplied clamp, leave this outlet facing
forward at this point (this will be turned to suit after fitting of the engine).Use a
webbing strap around the inlet manifolds and lift the engine using a suitable
hoist.
REMOVE THIS BOLT BEFORE FITTING ENGINE
DISCONNECT HOSES FROM WATERPUMP.
THE ANGLE OF THE PIPES MAY NEED
CHANGING ONCE THE ENGINE IS FITTED
FIT 600 MM LONG OIL HOSE TO RETURN OUTLET
(LEAVE FACING FORWARDS AT THIS POINT)
100
The long bolt removed from the top right hand side of the engine is re-fitted in
the same position, discard the two washers and fit spring washer (7495) from
bag 62. The remaining bolts and brackets are also in bag 62. Apply loctite 221
to bolt threads, align exhaust brackets (14052) as shown before tightening
lower bolts. Torque bolts to 40NM.
WASHER (7495)
1
1
BOLT REMOVED FROM ENGINE
2
BOLT (14477)
WASHER (7495)
2
BRACKET (14052)
3
3
WASHER (7495)
BOLT (14477)
4
4
WASHER (7495)
BOLT (14477)
BRACKET (14052)
101
SET THIS DISTANCE TO 190 MM BEFORE
TIGHTENING LOWER BOLTS
Fit locking plugs (51092) into each bolt head, drill through frame 2mm dia. and
fit split pins (10896). The lower plugs are easy to drill from underneath ( be
careful not to drill into the weld as this will break the drill). The upper plugs are
a little more difficult to drill and may require some engine components
loosening or removing to gain access.
LOWER LOCKING PLUGS
SPLIT PIN (10896)
LOCKING
PLUG (51092)
DRILLING FOR UPPER LEFT LOCKING PLUG
SPLIT PIN (NOTE COOLANT HOSE REMOVED)
SPLIT PIN (10896)
LOCKING
PLUG (51092)
102
SPLIT PIN (10896)
LOCKING
PLUG (51092)
TOP RIGHT LOCKING PLUG SPLIT
PIN HOLE BEING DRILLED
Re-connect the lower cooling hoses to the waterpump, adjust the positions of
the waterpump outlets as required for best clearance between the engine
frame and the coolant hoses. If required fit some protection sleeves where
chaffing may occur.
OIL TANK AND OIL SYSTEM
Fit oil tank to bracket on firewall using two jubilee clips (3422) from bag 66
(we fit a couple of long cable ties behind the upper clamp to secure the fuel
lines).
JUBILEE CLIP (3422)
LONG CABLE TIES TO
SECURE FUEL PIPES.
103
Fit the elbows to the tank and connect the pipe from the oil cooler to the one
marked OUT, secure with the supplied clamp.Loosen the banjo bolt on the
bottom of the crankcase and rotate the fitting to provide the best angle for
routing the hose up to the oil tank, connect this hose to the elbow marked IN.
secure hoses to engine frame with cable ties and protect from chaffing where
necessary. Tighten the banjo bolt and lockwire it and the oil tank drain plug.
Fit a 580 mm long piece of ¼” urethane tube to the oil tank vent and route it
down to exit at the bottom of the firewall.
OIL HOSE FROM BOTTOM
OF CRANKCASE
OIL HOSE FROM
OIL COOLER
580 MM LONG ¼”
URETHANE PIPE
ROUTE OIL PIPE FROM BANJO FITTING UP
TO OIL TANK (SECURE WITH CABLE TIES)
BANJO FITTING ON
BOTTOM OF CRANKCASE
104
If fitting the optional 90° elbow in the oil pump refer to the engine manual for
removal and re-fitting of the pump, apply loctite 648 to the threads of the
elbow, cut the already fitted oil pipe to length and fit using the supplied
clamps. If not fitting a 90° elbow cut suitable length of oil pipe and fit with the
supplied clamps. In both cases secure with cable ties and protect from heat
and chaffing as necessary.
OIL PIPE FITTING AT OIL PUMP WITH
OPTIONAL 90°ELBOW
Exhaust system bags 62 and 64
Fit the two front exhaust brackets (9984) using bolt M10 X 25 (14074) and
spring washer (7495), drill the head of the bolt before fitting to accept wire
locking. Do not tighten or wire lock these until the whole exhaust system is
assembled.
BOLT M10 X 25
(14074)
WASHER (7495)
BRACKET (9984)
105
Loosely assemble the exhaust (bag 64) to the engine complete with the
supporting clamps (9689) bag 170 and if the heater is being fitted the hot air
collector goes on top of the silencer box and is clamped in position by the
same two clamps. Tighten exhaust pipes to cylinder heads first, then the
clamps around the silencer and finally the clamps securing the pipes into the
silencer box, the aim is to not have any of the pipes stressed. Turn pipes in
cylinder heads to get clearance from the oil filter etc. The hot air collector and
clamps should be positioned as shown in the following drawings/photographs.
REAR EXHAUST PIPE
(63572)
FRONT RIGHT
EXHAUST PIPE
(15223)
CLAMP (7674)
FRONT LEFT
EXHAUST PIPE
(13857)
SILENCER (8709)
CLAMP (9689)
BOLT M5 X 50 (10453)
WASHER 5.3 (44870)
NUT (7494)
106
ADJUST TO PROVIDE ADEQUATE CLEARANCE
TIGHTEN AND LOCKWIRE THESE BOLTS LAST
107
Coolant overflow bottle bag No 65 and Light Sport supplementary
cooling kit
Drill a 5 mm hole in the side of the neck of the overflow bottle (56246) and
insert a 810mm long 1/8” urethane hose approximately 20mm into the neck.
Fit hose (7578) to the outlet on the bottom of the bottle and secure with cobra
clamp (7873). Fit bottle into holder on firewall and connect hose 7578 to
expansion tank on engine and secure with cobra clamp (7873), secure hose
to engine frame with cable ties as required. Route the overflow pipe down
towards the bottom of the firewall alongside the oil vent pipe.
BOTTLE (56246)
1/8” URETHANE HOSE
810 MM LONG FITTED
INTO HOLE 5MM
DIAMETER IN SIDE OF
NECK OF BOTTLE
COBRA CLAMP (7873)
HOSE (7578)
CARBURETTOR DRIP TRAYS AND CARBURETTOR HEATERS Bag 62
and Skydrive carburettor heater kit
Drill out the two holes in the side of each carburettor to 3.5 mm Ø to a depth
of 10 mm, now tap M4 to accept the screws to secure the drip trays.
108
Follow the instructions that came with the carburettor heating kit and press the
bodies onto the carburettors. Fit the drip trays (7415 and 7416) onto the
carburettors using screws M4 X 8 (48038) and washers 4.3 (6812), all from
bag 170. We bend the edge of the drip tray vertical flange to give better
clearance between it and the engine frame. Re-fit the carburettors to the
engine and tighten the clamps to secure. The clamps and brackets on the
balance pipe will need turning around so as not to overstretch the support
springs. Undo and rotate the fuel inlets on both carburettors so when the fuel
pipes are fitted they will clear the drip trays.
BEND THIS
EDGE TO CLEAR
ENGINE FRAME
SCREW M4 X 8 (48038)
WASHER 4.3 (6812)
ROTATE FUEL INLET SO
PIPES WILL CLEAR THE
DRIP TRAYS
TURN CLAMP AND BRACKET AROUND TO
PREVENT OVERSTRETCHING SUPPORT SPRING
109
FUEL SYSTEM FIREWALL FORWARD BAG 46 AND SKYDRIVE FUEL PRESSURE
GAUGE KIT.
Cut and assemble the fuel pipes (7578) as drawn below, fit fuel lines to
aircraft as per the pictures, use cable ties to secure pipes and fit protection to
prevent chaffing where necessary.
FUEL RETURN CONNECTION ON
FIREWALL COBRA CLAMP 11/7
(3740)
FUEL FEED
CONNECTION ON
FIREWALL COBRA
CLAMP 12/8 (7838)
620
FUEL PRESSURE
GAUGE
GROMMET 152345 IN FIREWALL
1260
820
COBRA CLAMP 11/7
(3740)
280
R/H Carb
150
COBRA CLAMP
11/7 (3740)
COBRA CLAMP 12/8
(7838)
130
COBRA CLAMP
11/7 (3740)
570
Fuel
pump
RESTRICTED
“T” PIECE
USE CLAMPS
SUPPLIED
WITH FUEL
PRESSURE
GAUGE
L/H Carb
RESTRICTED CROSS PIECE (30625)
(RESTRICTION TOWARDS RETURN PIPE)
COBRA CLAMP 11/7 (3740)
110
COMPONENTS FROM BAG 46
SECURE TO OIL TANK WITH CABLE
TIES AND PROTECTIVE SLEEVES
(MADE FROM COOLANT HOSE)
FUEL LINES SECURED TO IGNITION BRACKET
(NOTE SPACER MADE FROM OIL HOSE)
CONNECTION AT CARBURETTOR
ASSEMBLED FUEL LINE
CROSS PIECE AT REAR OF ENGINE
RESTRICTED “T” FOR FUEL PRESSURE GAUGE
CONNECTIONS AT FUEL PUMP
111
Cooling system and carburettor heating pipework bag 65, Light Sport
supplimentary cooling kit and carburettor heat kit.
Cut the top hose from the engine expansion tank to No 2 cylinder and fit the
small “T” piece from the carburettor heat kit using the supplied jubilee clips (if
you have opted to fit a coolant temperature gauge there will be a different “T”
piece with a fitting for a temperature sender). Follow the diagram below and
connect the hoses to the “T” pieces and the carb heater bodies, use the 25
mm hose (26229) and jubilee clips (3495) from bag 65 to connect the large
“T” piece to the waterpump inlet. Use the clamps supplied with the carburettor
heater kit to secure the ¼” hose to the heater bodies and “T” pieces. Cable tie
the hoses as required to prevent chaffing.
¼” FUEL HOSE
600
CARB HEATER
CYL. 1 & 3
600
180
CARB HEATER
CYL. 2 & 4
25 MM “T” PIECE
17 MM “T” PIECE IN HOSE TO
TOP OF CYLINDER NO 2
60
50
WATER PUMP INLET
ELBOW
25 MM RUBBER HOSE (26229)
SECURE WITH JUBILEE CLIP (3495)
112
CARBURETTOR HEATER COOLANT PIPE
AT “T” PIECE IN TOP HOSE
OUTER CONNECTION AT
RIGHT HAND HEATER BODY
CARBURETTOR HEATER COOLANT PIPES
AT LEFT HAND HEATER BODY
PIPE JOINING HEATER BODIES
CABLE TIED TO BALANCE PIPE
CONNECTIONS AT WATER PUMP INLET
RIGHT HAND HEATER BODY INNER
CONNECTION (PIPE ROUTES DOWN TO
WATERPUMP OUTLET)
113
Using one of the rubber elbows from the Light Sport supplementary cooling kit
connect pipe (17251) to the outlet on the expansion tank. The pipe routes
down in between the engine frame and then forward inside the No 4 cylinder
exhaust pipe. Cut the rubber elbow to length as necessary and secure with
jubilee clips (3495) from bag 65. This pipe will be secured with cable ties and
anti-chaffing protection added as necessary once it has been connected to
the radiator and it’s final position identified.
RUBBER ELBOW
JUBILEE CLIPS
(3495)
PIPE (17251)
RUBBER ELBOW
JUBILEE CLIPS
(3495)
114
Fit pipe (17239) with jubilee clip (3495) onto the rubber pipe connected to the
“T” piece on the waterpum pinlet, do not tighten this clip yet.
JUBILEE CLIP (3495)
PIPE (17239)
To make the connections to the radiator the lower cowling needs to be fitted
complete with the radiator. The right hand pipe (17239) is joined to the
radiator using a piece of hose (26229) and jubilee clips (3495), adjust the
length of hose to get the best fit and clearance from adjacent components.
The left hand pipe is connected to the radiator using a cut down rubber elbow
from the Light Sport supplimentary cooling kit and is secured with jubilee clips
(3495). Once all the pipes are adjusted for best fit and are clear from potential
chaffing and heat sources tighten all the clamps fully and secure where
necessary with cable ties. Now when the cowling is removed the four screws
holding the radiator to the cowling are removed and the radiator remains
connected to the engine.
RIGHT HAND RADIATOR CONNECTION
RUBBER ELBOW
HOSE (26229)
JUBILEE CLIP (3495)
JUBILEE CLIP (3495)
LEFT HAND RADIATOR CONNECTION
115
Instrument panel bag 75, bag 55, Light Sport instrument and electrical
kits
The panel is supplied without the holes for instruments cut; a cutting plan is
supplied by Light Sport, which shows the layout of instruments, switches,
throttle and choke controls. The builder can either follow this cutting plan or
design their own layout. It is, however, recommended that the throttle and
choke controls are mounted as shown. The panel is secured to the aircraft by
means of Rivnuts in the cross member and around the instrument panel
coaming (these may have already been fitted at the factory). Align the panel
to the coaming and level with the cross member, drill through the pre drilled
holes in the panel into the cross member and coaming. Remove the panel
and open the holes in the cross member and composite coaming up to
6mmØ. Fit Rivnuts (6980) placing washer (13940) behind the composite
coaming to support the Rivnuts.
RIVNUT (6980)
WASHER (13940)
The following shows how we completed the instrument panel and electrics,
this of course may vary depending upon individual instrument fits. Bag No 75
contains switches, fusebox, mounting brackets and the fuel gauge.
Buss bar
HEAT SHRINK TUBING
Cut and bend buss bar (8716) as
shown and fit heat shrink tubing from
Light Sport electrical kit over the
terminals
BUSS BAR (8716)
116
Fuse box
SCREW M4 X 20
(51883)
SPACER
(7523)
WASHER 4.3
(6812)
NUT M4
(3088)
BUSSBAR
(8716)
FUSE HOLDER
(7452)
HOLDER
(7520)
SCREW M4 X 20
(51883)
SPACER
(7523)
NUT M4
(3088)
WASHER 4.3
(6812)
117
Fuel level gauge bag No 75
STIRRUP (13832)
GAUGE
(7186)
NUT M4
(6455)
WASHER 4.1 (20982)
Instruments, switches and wiring.
We fitted all the instruments, switches and pre-wired the panel before fitting it
to the aircraft.
12-VOLT SOCKETS
NOT USED
+ CONNECTION
EARTH CONNECTION
1
2
3
4
1 – OIL PRESSURE GAUGE
2 – CYLINDER HEAD TEMPERATURE GAUGE
3 – OIL TEMPERATURE GAUGE
4 – BATTERY VOLTAGE
5 – FUEL LEVEL GAUGE
6 – STARTER WARNING LED
7 – STARTER BUTTON
5
7
8
118
FUSE BOX AND SOCKETS
2
6
1
5
3
7
6
8
Mark limits on instruments, see pilots operating handbook for limits.
CT Aviation Instrument marking kits are available from Light Sport Aviation.
119
REAR VIEW OF PANEL
WIRING ON BACK OF PANEL
WIRING AT FUSEBOX
WIRING AT SWITCHES AND INSTRUMENTS
Connect together the static ports
on ASI, VSI and altimeter with ¼”
urethane tube and “T” connectors
from the Light Sport flight
instrument kit.
The panel is secured into the aircraft using countersink allen screws and
cupped washers from bag 55, the screw below the throttle control is secured
by a washer and M4 nut after it passes through the throttle support bracket. It
is easier to fit the throttle and choke controls before completing the wiring,
pitot/static lines etc.
120
Throttle control bag 70)
Fit the two grommets (3783) in the upper two holes in the centre of the
firewall. Dismantle the throttle control (14478) as shown in the photos below
by unscrewing the aluminium slider assembly from the plastic piece, then
slide the ring out of the plastic part and disengage the ball joint. Unscrew and
remove the large nut and washer.
Fit the throttle control through the hole in the instrument panel, fit spacer and
bracket,drill and rivet bracket to crossmember, fit washer and nut. Reassemble throttle slider before tightening the securing nut.
BRACKET
3 X RIVET HERE
SPACER (10466)
121
Cut two lengths of outer cable (3558), one 770 mm long to run to the left hand
carburettor and one 1000 mm long for the right hand carburettor. Slide the
outer cables over their respective inner cables, through the grommets in the
firewall and into the recesses in the throttle slider. Fit two “grommets” from the
Light Sport supplementary throttle kit over the end of each outer cable
followed by end cap (3551) and connect them to the carburettors. With the
throttle slider set at idle (pulled fully out) set the cables so the levers are both
just touching the idle stops (the carburettors are configured to spring to the
fully open position so will need holding closed whilst the cables are set).
Check both carburettors open fully when the control is pushed fully in. Once
these are set wind the throttle stops back one full turn so that when the
throttle control is in the idle position there is a small gap between the levers
and the stops, when the pneumatic synchronization of the carburettors is
done ensure this gap remains to avoid stressing the cables and levers when
pulling on the throttle control. Cut off any excess cable and solder the ends to
prevent fraying, fit cable ties to secure the “grommets” and prevent the outer
cables jumping out of their fittings on aggressive throttle openings. Secure
cables as necessary to engine frame to prevent chaffing.
RUBBER “GROMMET”
R/H
1000
END CAP
(3551)
SMALL CABLE TIE
AROUND “GROMMET
“AFTER FITTING
GROMMET (3783) IN
FIREWALL
OUTER CABLE
(3558)
L/H
770
Right hand carburettor with
“grommet” secured with cable ties.
Left hand carburettor, note
routing of throttle cable and
cable tie securing it to the
engine frame.
122
Choke cables Light Sport choke kit.
END CAP
“GROMMET”
760
END ADJUSTER
WASHER
NUT
1/8” URETHANE
80 MM LONG
“GROMMET”
END CAP
CHOKE INNER CABLE
340
CABLE TIE “GROMMETS” IN POSITION
123
Pitot/static lines
Connect the pitot line to the connection marked “pitot” on the airspeed
indicator. Connect the static line to the “T” piece which connects to all of the
instruments static connections.
Fuel pressure gauge
Connect the fuel pressure line (from the restricted “T” piece in the fuel line to
the left hand carburettor) to the gauge and secure with clamp from the fuel
pressure gauge kit.
STATIC LINE
PITOT LINE
FUEL PRESSURE GAUGE
Completing the electrical system Light Sport electrical kit
Fit the supplied engine earth cable, one end on the bottom bolt of the water
pump outlet elbow and route along the engine frame to the negative terminal
on the battery (do not connect this yet). Fit a rubber cover to each end of the
shorter red battery cable; connect one end to the battery positive terminal and
the other to the right hand terminal on the starter solenoid. The longer red
cable goes between the other terminal on the starter solenoid and the starter
motor; fit a cover over the solenoid end. The following pictures and wiring
diagram shows how the rest of the electrical system is completed (this will
vary according to individual instrument and accessory fitments.
124
EARTH POINT
EARTH CABLE
RPM CONNECTOR
125
MASTER, CHARGING AND STARTER CIRCUITS
STARTER
SOLENOID
STARTER MOTOR
NOTE WIRE FROM SOLENOID
TO GOLD COLOURED
TERMINAL ON LED
0.5 MM²
STARTER WARNING LED
0.5 MM²
STARTER SWITCH
3A
1A
3A
BUSS BAR
2.5 MM²
0.5 MM²
1A
5A
CHARGING SWITCH
2A
1A
10 A
2.5 MM²
2.5 MM²
25 A
2.5 MM²
25 A
10 MM²
MASTER SWITCH
2.5 MM²
REGULATOR CONNECTOR BLOCK
2.5 MM²
G G R B L C
–
+
+
2.5 MM²
0.5 MM²
–
CAPACITOR
10 MM²
2.5 MM²
FROM ENGINE
BATTERY
EARTH POINT
ON ENGINE
EARTH POINT
BEHIND PANEL
126
IGNITION SWITCH WIRING NOTE – IGNITION IS LIVE WITH CIRCUIT
OPEN
IGNITION SWITCH “A”
3 CORED SHIELDED CABLE
(USE TWO BLACK WIRES ONLY)
CONNECT SHIELD
TO SWITCH
SECURING BOLT
CONNECT SHIELD TO
EARTH BOLT ON
IGNITION MODULE
CONNECT INTO MULTI PLUG ON
IGNITION UNITS AS PER PICTURES ON
PAGE 124
IGNITION SWITCH “B”
SPARE - GPS, TRANSPONDER ETC
BUSS BAR
3A
1A
3A
0.5 MM²
GPS OR
TRANSPONDER ETC
1A
5A
2A
1A
10 A
25 A
25 A
AUXILIARY FUEL PUMP (EV97A AND OPTIONAL ON MICROLIGHT
VERSION)
BUSS BAR
3A
1A
3A
2.5 MM²
AUXILIARY FUEL
PUMP SWITCH
1A
5A
2A
1A
10 A
25 A
25 A
127
AUXILIARY FUEL PUMP
ENGINE INSTRUMENTS, REV COUNTER AND FUEL GAUGE
NOTE, BLUE AND YELLOW WIRES REVERSED AT GAUGE
0.5 MM²
0.5 MM²
0.5 MM²
FUEL GAUGE
FUEL LEVEL SENDER
BUSS BAR
3A
1A
3A
1A
RPM PICK UP
ON ENGINE
0.5 MM²
5A
2A
1A
10 A
0.5 MM²
1
2
3
ROTAX 2 PIN PLUG
AND SOCKET
0.5 MM²
25 A
REV COUNTER
25 A
0.5 MM²
–
+
BATTERY VOLTAGE
+
CHT SENDER IN
N°3 CYLINDER
–
S
0.5 MM²
CHT GAUGE
+
–
OIL TEMPERATURE
SENDER
S
0.5 MM²
OIL TEMPERATURE GAUGE
OIL PRESSURE SENDER AND GAUGE
SHOWN IS ROTAX LATEST TYPE
BLACK WIRE NOT USED
+
S
OIL PRESSURE GAUGE
+
S
OIL PRESSURE
SENDER
WHITE WIRE TO EARTH
–
0.5 MM²
VDO OIL PRESSURE SENDER AND GAUGE
128
12 VOLT SOCKETS AND COMMS
ANTENNA
BUSS BAR
3A
1A
3A
0.5 MM²
TRANSCEIVER
1A
5A
2A
1A
10 A
INTERCOM
25 A
25 A
HEADSET SOCKETS
P/ & P2 PTT
SWITCHES
0.5 MM²
0.5 MM²
NOT USED
NOTE, FOLLOW THE WIRING INSTRUCTIONS FOR
THE CHOSEN INTERCOM/TRANSCEIVER
12-VOLT SOCKETS
Scuttle panel stiffener
The stiffeners (bag 3) have to be aligned onto the scuttle panel as shown
below, drilled and clecoed in place. Cut the excess from the ends of the
stiffeners, approximatelt 10 mm after the last rivet , apply emfimastic and rivet
in place using rivet 3.2 x 7.9 (6472).
TRIM OFF EXCESS APPROX. 10
MM PAST LAST RIVET BEFORE
RIVETING IN PLACE
375
180
129
The panel, when completed is secured to the fuselage with screw M4 X 12
(51655), put a plastic washer (56125) under the head of each screw. Screws
and washers are in bag 2.
Propeller and spinner. Bag 60 & bag 9
The spinner will require cutting to suit the propeller being used (it may
already be marked out fot the two bladed VZLU propeller). The back
plate(7948) requires the fitting of nut plates (59251) to secure the spinner
cone and may also require the drilling of additional holes for the propeller
mounting bolts. The studs, collar nuts and castle nuts ETC in bag No 9 are for
fitting the VZLU propeller and may or may not be suitable for other propellers.
Refer to the instructions supplied with the chosen propeller for fitting. The
installation shown in the following pictures is for the Kiev 273/1700 three
bladed propeller. Set pitch to 28° @ 350 mm radius this should give a static
RPM of 4600.
130
DRILL AND CLECO SPINNER
CONE TO BACK PLATE
DRILL 3.2 MM AND COUNTERSINK
HOLES FOR RIVETS
NUT PLATE (59251)
RIVET 3.2 X 9.5
(6796)
KIEV PROPELLER FITTED USING BOLTS
SUPPLIED WITH PROPELLER
Wings
Wing tips
The wing tips have already been pre-fitted at the factory and the rivet holes
drilled, apply emfimatsic and rivet the tips in place using rivet 3.2 x 7.9 (6472)
from bag No 15.
APPLY EMFIMASTIC, CLECO WING TIPS IN PLACE AND RIVET
WITH 3.2 X 7.9 (6472) RIVETS.
131
Pushrods Bag no 35
Set the length of the long pushrods (8689) to 2314 mm from the centre of the
rose joint to the centre of the inner fork bolt hole, align the rose joint so that
when fitted to the aileron bell crank the bolt through the root connection will be
horizontal.Set the two short rods (8690) to 712 mm between rose joint
centres, align the rose joints at 90° to each other. Tighten all lock nuts and
paint a red line across them to make later inspection easier. Lubricate all ball
joints before fitting
PUSH RODS (8689)
2314 MM
PUSH RODS (8690), NOTE ROSE
JOINTS SET AT 90° TO EACH OTHER.
712 MM
Remove the panels on the underside of each wing to gain acess to the aileron
bell crank.Fit the short rods (8690) between the aileron horns and the bell
crank inside the wing.Pay particular attention to the part No and position of
the washers.Fit the long pushrods (8689) into the wing and connect to the bell
crank.
132
WASHER 6.4
(66302)
NUT (3062)
SCREW 6 X 23
(62369)
SPLIT PIN
(8530)
NUT (3062)
SCREW 6 X 23
(62369)
SPLIT PIN
(8530)
WASHER 6.4
(66302)
6813
NUT (3062)
WASHER 6.4
(6813)
SPLIT PIN
(8530)
WASHER 6.4
(66302)
WASHER 6.4
(6813)
SCREW 6 X 23
(62369)
133
Pitot static head Bag No 49
Insert pitot head(13596) into the fibreglass housing approximately 20mm,
mark and drill a 2.5 mmØ hole in each side of the housing, drill through into
the pitot tube 2 – 3 mm. Remove tube and tap the two holes in the housing
M3, drill the two holes in the pitot head out to 3 mmØ and 3 mm deep.
PITOT HEAD (13596)
SCREW M3 X 6
Feed the pitot and static pipes already installed in the wing through the
housing ,these are already marked PITOT and STATIC and it is a good idea
to mark them where they exit the at the wing root, connect the pipes to the
pitot head (Evektor supply some locking wire to wrap around these
connections but we have found it not to be necessary). Push pitot head into
the housing and secure with screws M3 X 6 (12171). Screw pitot head
assembly to wing using screw M4 X 12 (51655), put a plastic washer (56125)
under each screw. The pitot and static labels supplied by Evektor tend not to
stick so we prefer marking the pipes with a permanent marker.
134
Now is a good time to fill all of the rivet heads on the wings, not forgetting the
rivets on the root rib and in the aileron and flap bays. It is also much easier to
fit the registration letters before the wings are fitted to the fuselage. The
aileron trim tab, bag 15 (E3 02-21 21) should now be fitted on the underside
of the starboard aileron using rivets 3 X 6.7.
Fitting wings to fuselage bag 16
Apply lubrication to the fuselage and wing attachment lugs to ease assembly,
align the wings with the spar attachments and fit pins (8484) top and bottom,
fit bolt (2858) in the rear spar attachments. Put a washer (8383) on each main
pin and secure with safety pin (3952). Secure the rear spar attachment bolt
using washer (6814), nut (13616) and safety pin (3952).
PIN (8484)
SAFETY PIN
(3952)
WASHER (8383)
BOLT (2858)
NUT (13616)
SAFETY PIN
(3952)
WASHER (6814)
135
Flap operating levers bag 51
Assemble the operating levers, screw the eccentric pins (7300) into levers
(7029) as far as they will go, then back them off until they are in the mid
position, this gives fine adjustment of the flaps in both directions if required
(mid position is with the pin either forward or rearward of the threaded portion
and will depend on alignment in the flap slot). Lock the pin with washer (6814)
and nut (7810).
WASHER
(6814)
ECCENTRIC PIN (7300)
NUT 97810)
LEVER (7029)
NOTE, RECESS IN LEVERS FACE TOWARDS
FUSELAGE WHEN FITTED.
SET ECCENTRIC PIN AT THE MID POSITION, EITHER FORWARDS OR
REARWARDS
With the flap control in the retracted position (lever fully down/forward) fit the
assembled operating levers onto the torque tubes and engage the pins into
the slots in the root of the flaps. The slot in the root of the flaps may require a
little filing to allow the pin to move smoothly in it. Holding the flaps fully up
against the underside of the wing, and with the pins correctly engaged in the
flap, drill through the lever pilot holes from the top and bottom. The bolt holes
can now be progressively opened up to finished size (6mm Ø) from one side
only (top or bottom). Fit bolt (8491) with washers (6813) and nut 3089).
Measure and record the flap deflections, these should be 15°±2°, 30°±3 and
50°±3°. MaxImum difference between flaps is 2°.
136
BOLT (8491)
WASHER (6813)
WASHER (6813)
NUT (3089)
THIS SLOT MAY REQUIRE
FILING TO ALLOW PIN TO
ALLOW PIN TO SLIDE
SMOOTHLY
137
Pitot and static lines
Connect the clear flexible pitot and
static hoses to the aluminium tubes at
the wing root; the tubes require
bending slightly to prevent kinking the
flexible hoses. We have not found the
need to fit any form of retaining clip at
this junction. Carry out a pitot/static
leak test when completed.
Aileron pushrod connection and adjustment
Using masking tape fix both ailerons level with the trailing edge of the wing,
adjust one of the short rods from the control sticks so that the bolt (2836) can
be fitted connecting the two rods together whilst having the control stick
vertical (we measure the distance from the sticks to the edge of the cockpit sill
and adjust the short rod to get them equal). With one side set it is a simple
matter of adjusting the other side enough to be able to fit the bolt. The result
of this should be, both ailerons level and both control sticks vertical. Secure
the two bolts with washer (6813), nut (3070) and split pin (8530).
BOLT (2836)
WASHER (6813)
NUT
(3070)
SET AILERONS LEVEL USING
MASKING TAPE
SPLIT PIN (8530)
138
Remove the masking tape from the ailerons and using the stop adjusters at
the base of the control sticks set the aileron deflections to 20°±1° up and
15°±1° down. Lock the adjusters and mark with red paint. The lock nut on the
short aileron rod at the wing root can now be tightened, the rose joint must be
positioned to allow full fore and aft movement of the stick without the rose
joints binding I.E. there is some rotational free play in the rods at the extremes
of fore and aft stick positions. This can take a while to get right, once
tightened put a red line across the lock nuts to aid future inspection.
SET AILERON DEFLECTIONS TO –
20°±1° UP AND 15°±1° DOWN.
ADJUSTING AILERON STOPS
Wing root fairings
Prepare the upper wing root fairings by gluing the edge protection/trim, (7526)
bag 17, to them.
139
Fit the upper fairings to the airfraft, drill and cleco in position as shown in the
picture below, position the fairing si that it is “sprung” against the fuselage
side. The one fixing in the fuselage side only needs fitting if the fairing is not
tight against the fuselage side at this position.One further hole not shown is
under the rear of the fairing through the bracket attached to the fuselage.
FIT ONLY IF REQUIRED
380
300
140
290
10
160
Drill the lower fairing as shown and cleco in place, the two final holes are
drilled through the upper and lower fairings to attach them together and to the
underside of the wing at the front.
DRILL THROUGH BOTH FAIRINGS, WITH FAIRINGS FITTED, AND FIT
RIVNUT IN ALUMINIUM FAIRING
10
180
160
150
195
35
DRILL THROUGH FAIRING INTO BRACKET ON
FUSELAGE
DRILL THROUGH BOTH FAIRINGS, FIT
RIVNUT TO ALUMINIUM FAIRING
ALIGN FAIRING INNER EDGE ALONG
THE CENTRE LINE OF THE OUTER
ROW OF FUSELAGE RIVETS
140
20
DRILL THROUGH BOTH FAIRINGS, FIT
RIVNUT TO ALUMINIUM FAIRING
Remove the fairings, drill the holes in the fairings where screws are to pass
through out to 4.5 mmØ and the holes where rivnuts fit to 6 mmØ. Fit rivnits
(6980) and fit fairings using screws (51655) and plastic washer (56125), all
from Bag 16.
Apply the registration letters and graphics/placards. These can be obtained
from CT Aviation 07885 600047 or email chris@ctaviation.co.uk
It is now time for the final inspection, levelling checks, weight and balance,
engine runs etc.
Engine runs/ carburettor balance and fuel flow checks
Carry out initial engine runs as per the Skydrive installation check list supplied
with the engine.
Weight and balance
The weight and balance souuld be carried out with full oil, full coolant, 2.9
litres of fuel in the tank (unusable) and the aircraft levelled using the cockpit
sill as the reference. Use a couple of plumb lines to beasure the position of
the nose and main wheels reference to the wing leading edge. An attached
sheet has all of the relevant moment arms. Complete the LAA weight and
balance schedule.
Levelling checks
Carry out a levelling check and record the results on the sheet supplied.
Control deflection record.
Measure and record the control deflections on the supplied sheet.
141
Weight and balance Record
MODEL
EV97
REGISTRATION
G-
SERIAL N°
LAA-315-
FULL OIL AND COOLANT, 2.9 LITRES UNUSABLE FUEL
CONFIGURATION
WEIGHING POINT
SCALE READING
TARE
R (LBS) OR (9KG)
T (LBS) OR (KG)
NOSE WHEEL
RN =
TN =
LEFT WHEEL
RL =
TL =
RIGHT WHEEL
RR =
TR =
TOTAL WEIGHT (LBS ) OR (KG)
NET WEIGHT
NW = R-T (LBS OR (KG)
NWN =
NWL =
NWR =
TW =
TW = NWN + NWL + NWR = ………… + …………. + …………..
C.G. POSITION FROM DATUM (LEADING EDGE ) (IN) OR MM)
C.G =
C.G = NWL + NWR x b – NWN x a = (……. + ………) x …….. - …….. x ……..
TW
………….
G.G. POSITION (% MAC)
C.G =
C.G. (%MAC) =
C.G.(IN) OR (MM) x 100 = ………… x 100
MAC (IN ) OR (MM)
WEIGHING CARRIED OUT BY
PERMITTED C.G. RANGE OF
EMPTY AIRCRAFT IS 18 ± 2 %
DATE
142
LEVELLING RECORD
MODEL
EV97
POINTS
1 – 13
REGISTRATION
G-
SPECIFIED VALUES
MEASUREMENT
POINTS
DIFFERENCE
1 – 13
0
3 – 15
0
6 – 17
0
8 – 17
0
13 – 18
0
15 – 18
0
3 – 15
6 – 17
8 – 17
13 – 18
15 – 18
SERIAL N°
LAA-315-
LEVELLING CARRIED OUT BY
TOLERANCE
ACTUAL
DIFFERENCE
± 0.8 in
± 20 MM
± 0.8 in
± 20 MM
± 0.4 in
± 10 MM
DATE
143
CONTROL SURFACES DEFLECTION RECORD
MODEL
EV97
REGISTRATION
G-
SERIAL N°
LAA-315SPECIFIED
DEFLECTION
LONGITUDINAL
CONTROL
LATERAL
CONTROL
RUDDER
CONTROL
WING FLAPS
ELEVATOR UPWARD DEFLECTION
25° ± 1°
ELEVATOR DOWNWARD DEFLECTION
20° ± 1°
LEFT AILERON UPWARD DEFLECTION
20° ± 1°
LEFT AILERON DOWNWARD DEFLECTION
15° ± 1°
RIGHT AILERON UPWARD DEFLECTION
20° ± 1°
RIGHT AILERON DOWNWARD DEFLECTION
15° ± 1°
RUDDER LEFT DEFLECTION
30° ± 2°
RUDDER RIGHT DEFLECTION
30° ± 2°
LEFT FLAP DEFLECTION IN “TAKE OFF” POSITION
15° ± 2°
LEFT FLAP DEFLECTION IN “LANDING” 1ST POSITION
30° ± 3°
LEFT FLAP DEFLECTION IN “LANDING 2ND POSITION
50° ± 3°
RIGHT FLAP DEFLECTION IN “TAKE OFF” POSITION
15° ± 2°
RIGHTFLAP DEFLECTION IN “LANDING” 1ST POSITION
30° ± 3°
RIGHTFLAP DEFLECTION IN “LANDING 2ND POSITION
50° ± 3°
MAX. DIFFERENCE BETWEEN FLAP DEFLECTIONS
HTU
TRIM TAB
2°
MAX. DOWNWARD TRIM TAB DEFLECTION
5° ± 2°
MAX. UPWARD TRIM TAB DEFLECTION
25° ± 5°
CONTROL SURFACES DEFLECTION COMPLIANCE
YES
–
MEASURED
DEFLECTION
NO
MEASUREMENTS CARRIED OUT BY
DATE
144
USEFUL CONTACTS
EUROSTAR TECHNICAL ADVICE AND SPARE PARTS
LIGHT SPORT AVIATION 01494 524020
ROTAX SPARE PARTS
SKYDRIVE LTD 01926 612188
REGISTRATION LETTERS, GRAPHICS AND PLACARDS
LIGHT SPORT AVIATION 01494 524020
LAA (LIGHT AIRCRAFT ASSOCIATION)
01280 846786
ROTAX ENGINE SERVICE AND REPAIRS
LIGHT SPORT AVIATION 01494 524020
145